SEBU6400-06 (en-us) February 2016

Cat Gas Engine Lubricant, Fuel, and Coolant Recommendations All Gas Engines

Special Publication

SAFETY.CAT.COM i06558969 Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards, including human factors that can affect safety. This person should also have the necessary training, skills and tools to perform these functions properly. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you verify that you are authorized to perform this work, and have read and understood the operation, lubrication, maintenance and repair information. Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved. The message that appears under the warning explains the hazard and can be either written or pictorially presented. A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. You must not use this product in any manner different from that considered by this manual without first satisfying yourself that you have considered all safety rules and precautions applicable to the operation of the product in the location of use, including site-specific rules and precautions applicable to the worksite. If a tool, procedure, work method or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that you are authorized to perform this work, and that the product will not be damaged or become unsafe by the operation, lubrication, maintenance or repair procedures that you intend to use. The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Cat dealers have the most current information available.

When replacement parts are required for this product Caterpillar recommends using Cat re- placement parts. Failure to follow this warning may lead to pre- mature failures, product damage, personal in- jury or death.

In the United States, the maintenance, replacement, or repair of the emission control devices and systems may be performed by any repair establishment or individual of the owner's choosing. SEBU6400-06 3 Table of Contents

Table of Contents

Foreword ...... 4

Maintenance Section

Lubricant Specifications ...... 5

Fuel Specifications ...... 28

Cooling System Specifications...... 34

Reference Information Section

Reference Materials ...... 43

Index Section

Index...... 44 4 SEBU6400-06 Foreword

Foreword To reduce the potential risk of failures associated with extended oil drain periods; it is recommended that oil drain intervals only be extended based on oil Literature Information analysis, and subsequent engine inspections. Oil analysis alone does not provide an indication of the This manual should be stored in the literature storage rate of formation of lacquer, varnish and/or carbon on area. and other engine surfaces. The only accurate way to evaluate specific oil performance in a specific The information contained in this document is the engine and application that utilizes extended oil drain most current information available for coolants, fuels, and lubricants. Refer to the Operation and periods is to observe the effects on the engine Maintenance Manual for any special lubrication components. This involves tear-down inspections of requirements for your engine. engines that have run to their normal overhaul period with extended oil drain intervals. Following this Whenever a question arises regarding the engine, recommendation will help ensure that excessive this publication, or the Operation and Maintenance component wear does not take place in a given Manual, please consult any Cat dealer for the latest application. available information. NOTICE Light loads, low hour accumulation, and excessive Safety idling time can contribute to excessive water in the oil. Corrosive damage, deposits Refer to the Operation and Maintenance Manual for and increased oil consumption can also result. If oil your engine for all safety information. Read and analysis is not done or the results are ignored, the po- understand the basic safety precautions listed in the tential for corrosive damage and piston deposits in- Safety Section. In addition to safety precautions, this creases. Refer to the appropriate Operation and section identifies the text and locations of safety Maintenance Manual for guidance. signs used on the engine.

Read and understand the basic precautions listed in Note: Failures that result from extended oil drain the Safety Section before operating or performing periods are not warrantable failures, regardless of lubrication, maintenance and repair on this engine. use of this recommended procedure. Failures that result from extended engine oil drain periods are Maintenance considered improper use under the warranty. Refer to the Operation and Maintenance Manual for your engine to determine all maintenance Aftermarket Products and Warranty requirements. NOTICE Maintenance Intervals When auxiliary devices, accessories or consumables (filters, oil, additives, catalysts, fuel, etc.) made by Use the Maintenance Interval Schedule in the other manufacturers are used on Caterpillar prod- Operation and Maintenance Manual for your engine ucts, the Caterpillar warranty is not affected simply to determine servicing intervals. The actual operating because of such use. Failures that result from the in- environment of the engine also governs the stallation or usage of other manufacturers auxiliary maintenance interval schedule. Therefore, under devices, accessories or consumables, however, are extremely severe, dusty, wet or freezing cold not Caterpillar factory defects and therefore are NOT operating conditions, more frequent lubrication and covered by Caterpillar's warranty. maintenance than is specified in the Maintenance Interval Schedule may be necessary. Caterpillar is not in a position to evaluate the many auxiliary devices, accessories or consumables pro- Extended Engine Oil Drains and moted by other manufacturers and their effect on Cat- erpillar products. Installation or use of such items is Warranty at the discretion of the customer who assumes ALL risks for the effects that result from this usage. Failures that result from extended oil drain periods are not Caterpillar factory defects and therefore are Furthermore, Caterpillar does not authorize the use not covered by Caterpillar's warranty. In addition, of its trade name, trademark, or logo in a manner failures that result from not using the recommended which implies our endorsement of these aftermarket oil type are not Caterpillar factory defects and products. therefore are not covered by Caterpillar's warranty. Refer to the applicable Operation and Maintenance Manual for standard oil drain periods and to the Maintenance Section, “Lubricant Specifications” of this publication for engine oil type and viscosity grade recommendations. SEBU6400-06 5 Maintenance Section Lubricant Specifications

Maintenance Section Cat Fluids Cat fluids have been developed and tested by Cat in order to increase the performance and the life of Cat Lubricant Specifications components. The quality of finished oil is dependent on the quality of the base stock, the quality of the additives, and the compatibility of the base stock and i06559748 additives. Cat fluids are formulated of high quality refined oil base stocks and additives of optimal General Lubricant Information chemistry and quantity in order to provide high performance in engines and components. Cat fluids SMCS Code: 0645; 1000; 1300; 1348; 7581 are used for factory fill of Cat engines and Failure to follow the recommendations found in this components. These fluids are offered by Cat dealers Special Publication can cause engine failures, for service fills and as aftermarket products. Consult shortened engine service life, and reduced engine with your Cat dealer for more information on these performance. Cat fluids. In order to avoid potential damage to your Cat Cat recommends the use of the following Cat fluids engine, only purchase Cat fluids and filters through for Gas engines: your Cat dealer or Cat authorized outlets. For a list of authorized Cat parts outlets in your area, consult your Cat dealer. If you purchase what appear to be Cat fluids and/ or filters through other outlets/sources, you are at high risk of purchasing counterfeit products. Counterfeit products may visually appear the same as the original Cat product, but the product performance and internal quality will typically be very low. Counterfeit products have a high likelihood of causing and/or causing the engine and machine compartment damage. Use of fluids that do not meet at least the minimum performance recommendations and requirements may lead to lower compartment performance or compartment failure. Problems that are caused by using fluids that do not meet the minimum recommended or required performance level for the compartment are not warrantable by Caterpillar ® Inc. The fluid manufacturer and customer are responsible for any damage that is caused by use of these fluids. Refer to the Aftermarket Product and Warranty in the Foreword section of this Special Publication. Different brand oils may use different additive packages to meet the various engine performance category and specification requirements. For the best results, do not mix oil brands. The overall performance of engine and machine compartments is dependent on the choice of the lubricants and on the maintenance and cleanliness practices. These choices include filtration products, contamination control, fuel management, and general handling practices. Cat designed and produced filtration products offer optimal performance and system protection. 6 SEBU6400-06 Maintenance Section General Lubricant Information

Table 1 Caterpillar ® Lubricants Viscosity Grade

Cat Natural Gas Engine Oil Ultra 40 NGEO Ultra 40 SAE 40 Next Generation High Performance NGEO

Cat Natural Gas Engine Oil Advanced 40 NGEO Advanced 40 SAE 40 Premium Performance NGEO

Cat Natural Gas Engine Oil EL350(1) Premium Performance NGEO, Limited re- NGEO EL350 SAE 40 gional availability

Cat Natural Gas Engine Oil High Quality NGEO, Limited regional NGEO 40 SAE 40 availability

SAE 10W Cat HYDO Advanced SAE 20W Hydraulic Oil Cat Bio HYDO SAE 30 Advanced (HEES) ISO 46 Multigrade (1) Cat NGEO EL350 replaced Cat NGEO EL250

Table 2 Engine Oil Caterpillar Grease and Coolant Products Engine lubricants play multiple roles in engines. Cat Utility Grease Appropriate lubricants offer the following: Cat Prime Application Grease • Provides lubrication to the moving components of the engine under a wide range of temperatures Cat Extreme Application Grease

Cat Extreme Application Grease - Desert • Keeps the engine components clean and removes wear debris Grease Cat Extreme Application Grease - Arctic (Semi-Synthetic) • Removes heat from the lubricated components Cat Ball Bearing Grease • Neutralize acidic products due to combustion Cat White Assembly Grease process

Cat Hammer Plate • Protect the engine from cavitation Cat NGEC (Natural Gas Engine Coolant) • Protect the engine from corrosion and rust Cat DEAC ( / Coolants Coolant) • Control oil consumption

Cat SCA (Supplemental Coolant Additive) • Disperse/Solubilize contaminants (soot) for use with Cat DEAC Engines that use gaseous fuel require oils that are formulated with additives that are specific to these Note: Cat fluids availability will vary by region. engines. There are no industry standards that define the performance specifications of oils for these Always consult with the OMM of your engine to engines. Field evaluations must be used in order to determine the recommended oil for your specific determine oils that are acceptable. To aid in oil engine model. selection, guidelines are provided in this Special Publication. Always consult your Cat dealer in order to ensure that The following costs are associated with maintenance of the engine lubrication system: you have the current revision level of this publication. • Initial fill Note: The optimal application of the lubricants is dependent on the oil quality and the maintenance • Consumption practices such as contamination control, tank management, and general handling practices. • Analysis of the engine oil SEBU6400-06 7 Maintenance Section Engine Oil

• Replacement of the engine oil and engine Due to the significant variations in the quality and in the performance of commercially available oils, • Disposal of the used engine oil Caterpillar recommends the Cat Gas Engine Oils that are listed in Table 1 in the General Lubricant Maintaining the engine lubrication system is usually Information section. between 10 and 20 percent of the total cost of the engine maintenance. This percentage can be Cat natural gas engine oils are the preferred oils for affected by the type of fuel, the engine duty cycle, use in ALL Cat natural gas fueled engines that are and the maintenance practices. covered by this Special Publication. Commercial alternative natural gas engine oils are, as a group, The temperature of the cooling system, extended second choice oils. operation at light loads, and the condition of the engine (wear) have an effect on the rate of Cat natural gas engine oils are formulated of high consumption and on the engine oil service life. quality refined oil base stocks and additives of optimal chemistry and quality in order to provide Maintenance costs can be greatly increased by the superior performance in Cat natural gas engines. wrong engine oil. Inadequate lubrication that destroys moving parts causes expensive Cat NGEO products have been tested throughout the unscheduled down time. The following problems can world in demanding environments and have been result from the use of incorrect engine oil: tested in engines that use all types of gaseous fuel. Cat NGEO products are formulated and blended with • Buildup of varnish (glazing) in the liners special additives and high quality basestocks in order to provide protection against oxidation and nitration • Damage to bearings and to provide very good thermal stability. The formulations of these oils have been proven to be • Deposits on the valves that can lead to guttering of superior to many brands of available oil. the valves Cat NGEO products also provide the following • Oil coking in the benefits: • Piston rings and valves that stick • Reduction of the formation of carbon and sludge In order to achieve the lowest maintenance costs for • Resistance to foaming the lubrication system, use the recommended and preferred Cat natural gas engine oils. • Protection against cylinder liner wear Hydraulic Oil • Protection of valves and of valve seats • Improved cleanliness of pistons For information on hydraulic oil, see this Special Publication, “Hydraulic Oil” topic. • Protection against scoring of the pistons and scuffing of the pistons Lubricating Grease Table 3 lists the oil properties of Cat gas engine oils. For information on grease, see this Special The properties are based on ASTM test Publication, “Lubricating Grease” topic. specifications. Oils of higher viscosity will maintain the highest i06577132 possible oil film thickness. Engine Oil SMCS Code: 1348 Cat Gas Engine Oils

Cat natural gas engine oils have been developed and tested in order to provide the full performance and service life that has been designed and built into Cat natural gas engines. Cat oils are currently used to fill engines at the factory. These oils are offered by Caterpillar dealers for continued use when the engine oil is changed. Consult your Caterpillar dealer for more information on these oils. 8 SEBU6400-06 Maintenance Section Engine Oil

Table 3 Cat NGEO SAE 40 Viscosity Grade Properties

Characteristic ASTM Test Ultra 40 Advanced 40 Cat EL350 Cat NGEO Flash Point 0 ° C (32 ° F) “D0092” 247 252 247 252

Pour Point 0 ° C (32 ° F) “D0097” −21 −30 −21 —15

Viscosity (cSt) at 100 °C (212 °F) “D0445” 13 13 13.5 13.2

Viscosity Index “D2270” 95 min 103 97 98

Weight (Percent) of “D0874” 0.54 0.5 0.54 0.52 Sulfated Ash Total Base Number “D2896” 6 6 6.2 5.6

Engine Oil and Sour Gas Fuels Lube oils that are specifically designed for applications that use bio-gas are recommended. Many gaseous fuels contain sulfur compounds. These oils should have a concentration of sulfated These compounds are primarily composed of ash that is not greater than 0.6 percent. When possible, these oils should also be formulated with hydrogen sulfide (H2S). Gaseous fuels with less than Group II base stock. Group II base stocks have been 0.43 mg H2S/MJ (.45 µg H2S/Btu) are considered to be sweet gas. shown to provide reduced engine deposit buildup. The use of a lube oil with a high concentration of

Gaseous fuels with more than 0.43 mg H2S/MJ sulfated ash will result in excessive deposits in the

(.45 µg H2S/Btu) are considered to be sour gas. Sour . Because of the inconsistent, gas can reduce the service life of an engine and of variable composition of most bio-gas fuels, the lube the engine oil. When the sulfur compounds are oil may react differently to the composition of a combined with water, acids are produced in the particular fuel. Use the S·O·S oil analysis program to engine oil. These acids attack the metals in the determine the proper oil change interval. engine crankcase and in other components. This causes corrosive wear. To reduce the effects of these For new installations, sample the oil frequently in sulfur compounds, Caterpillar recommends the use order to establish a consistent program for oil of devices that treat the fuel. For further information, changes. Initially, sample the oil on a daily basis. The see this Special Publication, “Hydrogen Sulfide properties of landfill gas can change rapidly. Effects on Engine Maintenance Costs” in the Fuel Therefore, it is necessary to continue to monitor the Specifications section. oil on a weekly basis or two times per month in order to ensure adequate protection. Note: Caterpillar does NOT recommend the use of engine oils with a high concentration of sulfated ash (greater than 0.6 percent) in order to reduce the harmful effects of sour gas. High levels of sulfated ash (greater than 0.6 percent) may produce excessive deposits on the valves and on the turbine wheel of the turbocharger. These deposits will reduce the service life of the engine. These deposits will also increase the cost of maintenance. Engine Oil and Bio-Gas Fuels

Bio-gas fuels that are generated from landfill or digester gas power plants can include contaminants that react with the engine lube oil. This can create varied combustion deposits. Excessive deposits on the piston, the liner, and the can occur if the oil is not properly matched for the application. Laquering of the liner may also occur. SEBU6400-06 9 Maintenance Section Commercial Oils

Consult your local Caterpillar dealer for a Field evaluations may identify commercial brands of recommendation for lube oil for your bio-gas oil with successful results. Caterpillar will not endorse application. a commercial brand of oil because of the results. The oil company can use the results of the field evaluation as a proof of the oil performance. The oil company is S·O·S Services Oil Analysis responsible for the performance and the quality of the oil, and for any changes in the formulation of the oil. Caterpillar recommends the S·O·S oil analysis Before purchasing a lubrication oil for a gas engine, program in order to monitor the condition of the oil. discuss the claims of performance for the oil with the The analysis can help determine the maintenance oil supplier. requirements for the engine. The S·O·S program is part of the preventive maintenance program. For For additional details on the 7000 hour Field further information about the S·O·S program, see this Performance Evaluation, refer to this Special Special Publication, “S·O·S Services Oil Analysis” Publication, “Field Evaluation of Commercial Oil” topic. topic.

i06584566 i06586482 Commercial Oils Field Evaluation of SMCS Code: 1318; 1348 Commercial Oil Commercial oil specifications do not exist for Cat SMCS Code: 1348 engines that operate on gaseous fuels. The performance of lubrication oil for gas engines is Due to the significant variations in the quality and in determined by a field evaluation. Successful field the performance of commercially available oils, operation has been achieved with oils that meet the Caterpillar recommends the oils found in the tables following guidelines: below. • Caterpillar recommends the use of oils that are formulated specifically for heavy-duty gas engines. Do not use oils that are specially formulated for gasoline engines or for diesel engines. • Caterpillar does not recommend multigrade oils for use in gas engines.

• Caterpillar recommends the use of oils that have a sulfated ash content between 0.40 and 0.60 percent. • The oil must demonstrate adequate protection for a minimum of 7000 hours in a field evaluation under controlled conditions. 7000 Hour Field Performance Evaluation Caterpillar recommends oils for gas engines that meet the requirements of the 7000 hour field evaluation. The 7000 hours of field service must be documented. Standard and/or Low Emission engine configurations may be used for the evaluation. The field evaluation must be performed in an that is similar to the engine that will use the oil that is proposed. The field evaluation must be performed at a power level that is at least equal to the power that is required by the engine that will use the oil that is proposed. 10 SEBU6400-06 Maintenance Section Field Evaluation of Commercial Oil

Table 4 Caterpillar ® Lubricants Viscosity Grade

Cat Natural Gas Engine Oil Ultra 40 NGEO Ultra 40 SAE 40 Next Generation High Performance NGEO

Cat Natural Gas Engine Oil Advanced 40 NGEO Advanced 40 SAE 40 Premium Performance NGEO

Cat Natural Gas Engine Oil EL350(1) Premium Performance NGEO, Limited re- NGEO EL350 SAE 40 gional availability

Cat Natural Gas Engine Oil High Quality NGEO, Limited regional NGEO 40 SAE 40 availability

SAE 10W Cat HYDO Advanced SAE 20W Hydraulic Oil Cat Bio HYDO SAE 30 Advanced (HEES) ISO 46 Multigrade (1) Cat NGEO EL350 replaced Cat NGEO EL250

Table 5 Cat NGEO SAE 40 Viscosity Grade Properties

Characteristic ASTM Test Ultra 40 Advanced 40 Cat EL350 Cat NGEO Flash Point 0 ° C (32 ° F) “D0092” 247 252 247 252

Pour Point 0 ° C (32 ° F) “D0097” −21 −30 −21 —15

Viscosity (cSt) at 100 °C (212 °F) “D0445” 13 13 13.5 13.2

Viscosity Index “D2270” 95 min 103 97 98

Weight (Percent) of “D0874” 0.54 0.5 0.54 0.52 Sulfated Ash Total Base Number “D2896” 6 6 6.2 5.6

Cat natural gas engine oils are the preferred oils for Caterpillar Inc. is frequently approached by engine use in ALL Cat natural gas fueled engines that are owners and/or oil companies that wish to qualify an covered by this Special Publication. Commercial oil for use in gas engines. Caterpillar does not alternative natural gas engine oils are, as a group, recommend the names of other commercial brands second choice oils. of lube oils. However, Caterpillar will evaluate the results of the Field Performance Evaluation for Cat natural gas engine oils are formulated with the commercial brands of lube oils. The evaluation can correct amounts of additives and high quality verify that the oil meets the minimum lubrication basestock in order to provide superior performance in requirements that are recommended by Caterpillar. Cat natural gas engines. Caterpillar has established the following guidelines for the Field Performance Evaluation of lube oil in gas engines. These guidelines are applicable to the engines that use the following fuels: dry natural gas, sour gas and bio-gas. Operating Conditions for the Field Performance Evaluation Duration – The minimum number of operating hours for a G3300, G3400, G3500, and G3600 is 7000 hours. SEBU6400-06 11 Maintenance Section Field Evaluation of Commercial Oil

pistons, piston rings, cylinder liners and cylinder Load Factor – The load factor must be heads. These new components will be examined representative of the normal engine application at the during the final inspection. site. High load factors are preferred. Final Inspection – At the end of the Field Lube Oil – The oil must meet the requirements for Performance Evaluation, these components from two the oil properties that are described in this Special cylinders must be removed and inspected: Publication, “Engine Oil” topic. The oil must also meet the requirement for the formulation for gaseous fuel and the requirement for 0.40 to 0.60% sulfated • Pistons ash that are described in the “Commercial Oils” topic. • Piston rings Oil Analysis – Caterpillar recommends the S·O·S Services oil analysis program. Alternate oil analysis • Cylinder liners programs must measure oil condition and wear metals. Used oil samples must be obtained for • Cylinder heads analysis at 250 hour intervals. A baseline analysis of the new oil should also be obtained. • bearings Oil Change Interval – The oil change interval is None of the following conditions are acceptable: determined by condemning limits that are established by Caterpillar. The limits are based on analysis of the • Sticking of the piston rings used oil and the trend lines that are established. For typical oil change intervals, see this Special • Scuffing of the piston rings and/or cylinder liners Publication, “Oil Change Interval” topic. • Excessive wear of the piston rings Fuel Analysis – An analysis of the fuel must be provided by an independent laboratory at the • Polishing of the cylinder liner must be beginning of the Field Performance Evaluation. The confined to the area that is affected by the results from the gas analysis must meet the uppermost position of the top piston ring. guidelines of the engine models. For the guidelines, see this Special Publication, “Fuel Specifications” • The entire circumferences of the inlet valves and section. the exhaust valves must seal. • Guttering of the valves is not acceptable. Criteria for the Evaluation Close up photographs that show the wear and Oil Consumption – The oil consumption must not deposits must be taken in order to document the exceed two times the initial oil consumption during appearance of these components: pistons, piston the Field Performance Evaluation. The initial oil rings, cylinder liners, crankcase, top deck of the consumption is established during the first 1000 cylinder head, bottom deck of the cylinder head, inlet hours of operation with the oil that is being evaluated. valves and exhaust valves (bottom, face, and stem). In addition, two exhaust valve guides must be Valve Recession – The valves and the valve seats wear over time. This causes the valves to recede into removed from two cylinders and sectioned the cylinder head. This condition is called “valve lengthwise. Photographs that show the entire recession”. Measure the valve recession at the component must also be provided. engine commissioning. This measurement is the baseline. The baseline is a reference for subsequent Summary – This procedure for a field evaluation measurements. Measure the valve recession provides the oil company and the engine owner with according to the engine Operation and Maintenance a method of evaluating a lubricating oil for gas Manual, “Maintenance Interval Schedule”. The valve engines. If the oil meets these guidelines for the field recession must not exceed the limits that are evaluation, the oil has fulfilled the Caterpillar established for the engine by Caterpillar. Refer to the requirements. Caterpillar will not endorse any oil for engine Operation and Maintenance Manual, “Valve use in Cat gas engines as a result of field evaluation. Stem Projection - Measure/Record” topic for the The oil company can use the evaluation as proof of limits for the valve recession. performance. Parts Requirements – If a new engine is used for the Field Performance Evaluation, all of the engine cylinders must be inspected with a borescope during the final inspection. The cylinder that shows the worst deposits or wear and the cylinder that shows average deposits or wear must be used for the visual inspection. If a used engine is used to evaluate the oil, two new sets of these components must be installed before the Field Performance Evaluation: 12 SEBU6400-06 Maintenance Section Field Evaluation of Commercial Oil

Responsibilities • pistons • piston rings Care must be taken in order to define the responsibilities of each person that is involved in • connecting rod bearings the Field Performance Evaluation. The oil company and the engine owner must recognize the • cylinder liners responsibilities if the performance of the oil reduces the service life of the engine. Caterpillar recommends • cylinder heads specific definitions of the responsibilities for the oil company and the engine owner in a field evaluation. The cost should be covered by the oil company. An agreement should be made before the field These new components will be examined as part of evaluation is initiated. Both the oil company and the the final inspection. engine owner must understand that the Field Performance Evaluation is not monitored by Final Inspection – The cost of the final inspection Caterpillar. The field evaluation is not sponsored by should be paid by the oil company. If the final Caterpillar. inspection reveals severe deposits and/or damage to the hardware, the oil company must make the repairs Field Performance Evaluation Agreement that are necessary for restoring the engine to an acceptable condition. The Field Performance Evaluation agreement is End of the Evaluation – After completion of the between the engine owner and the oil company. The Field Performance Evaluation, the oil company agreement is a very important part of the field should work with the engine owner in order to restore evaluation. The completion and signing of the the engine to normal operation. If the Field agreement should occur before the initiation of the Performance Evaluation is not completed, the same field evaluation. The agreement must fully define the conditions should be applicable. The oil company field evaluation and the responsibilities of each party. should bear the cost of the restoration. This could This publication contains the information and include the cost for the removal of storage tanks, guidelines that are necessary to write a detailed special piping, flow meters, and instrumentation. agreement. The initial field evaluation involves some risk. Use of the guidelines will minimize the risk. If the Final Report – The oil company must prepare a final guidelines are followed, the probability of a report that documents the following items: successful field evaluation will be enhanced.

Responsibilities of the Oil Company • The data on oil consumption must be recorded on a minimum schedule of every two weeks. A chart Performance – The performance of the oil is the of the data must be included in the final report. responsibility of the oil company. The oil must maintain stable oil control and the oil must control • Results of the oil analysis must be plotted. deposits in the combustion chamber and in the crankcase. Engine service life must be maintained at • Oil changes the predicted stage for the particular engine application. • Replacement of the oil filters Supply – The supply of the oil is the responsibility of • Results of fuel analysis the oil company. If special storage and/or shipping is required, the oil company should cover the cost of • A histogram for fuel consumption or a histogram those items. for power output

Oil and Fuel Analysis – During the evaluation, the • A histogram for average engine speed oil company should pay for the cost of the oil and fuel analyses. The oil samples should be analyzed by a • The typical duty cycle Cat S·O·S Services regional lab or by the local Caterpillar dealer in the S·O·S Services program. • Valve recession The data that is obtained from the oil analyses must be plotted in order to establish trends. The fuel • Side clearance for the piston ring should be analyzed by an independent laboratory. Results of the oil and fuel analyses must be sent to • Valve guide to valve stem clearances the engine owner. The owner should review the data. Also, the owner should keep records of the data. Hardware – If the oil is evaluated in a used engine, two new sets of these components must be installed before the Field Performance Evaluation: SEBU6400-06 13 Maintenance Section Field Evaluation of Commercial Oil

• Close up photographs of the following Note: All associated travel, meals, and lodging are at components from two cylinders must also be the expense of the oil company. included: pistons, piston rings before removal and after removal, piston ring grooves after removal, Guidelines for the Use of A Proven cylinder liners, crankcase, top deck of the cylinder head, bottom deck of the cylinder head, inlet Lubricant In Other Engines valves (top and bottom), exhaust valves (top and (Interchanging) bottom), and valve guides. Interchanging – The information that is obtained The final report should be confidential. The final from most field evaluations will be applicable to other report must be made available to the engine owner gas engines at other sites. However, guidelines must and to Caterpillar,Inc.. be established in order to limit the application of a lubricant that has been evaluated. This is for the Responsibilities of the Engine Owner protection of the engine and the engine owner. The limit on the application of the lubricant is defined as Engine for the Evaluation – The owner must interchanging. provide access to the engine for the duration of the Field Performance Evaluation. Special piping and The interchanging of the lubricant is limited by these instrumentation may be attached to the engine for the factors: duration of the field evaluation. • The oil viscosity grade Operation and Maintenance – Daily operation and maintenance of the engine is the responsibility of the • The base stock of the oil owner. Operation and maintenance of the engine must follow the guidelines that are published by • The engine configuration Caterpillar in the engine Operation and Maintenance Manual. The daily records of this activity should be • The engine rating made available to the oil company. • The engine application Oil Samples and Fuel Samples – Oil samples and fuel samples will be collected by the owner. The • The engine load factor samples will be sent to the appropriate laboratory for analysis. • The fuel type Oil Viscosity Grade Caterpillar Responsibilities The recommended viscosity grade allows the Advisory – Caterpillar will not assume an active appropriate oil film thickness in order to support the function in the field evaluation. However, Caterpillar engine moving components and to minimize wear. will provide technical advice and guidance to the The ambient temperature recommended for SAE 40 parties that are involved. Caterpillar understands that viscosity grade oils is given in Table 6 . this function does not satisfy all of the situations that may arise in a field evaluation. Therefore, technical Table 6 judgments may be required for the initiation of some Engine Oil Viscosity evaluations. Ambient Temperature To provide assistance with the Field Performance Oil Viscosity Grade Evaluation, your Caterpillar dealer or district Minimum Maximum representative can consult the appropriate technical 5 °C (41 °F) 50 °C (122 °F) support personnel at Caterpillar Inc. SAE 40 Final Inspection – Under some circumstances, Caterpillar is asked to assist with the inspection. This Base Stock of the Oil is evaluated on an individual basis. The decision depends on the availability of personnel and on the Finished lubricants are made of base stocks and amount of technical interest. additives. Properly blended lubricants will have base stocks and additives that work together in order to consistently provide the following qualities: adequate control of deposits, adequate control of wear, adequate service life of the oil, stability to oxidation and nitration, and resistance to corrosion. 14 SEBU6400-06 Maintenance Section Field Evaluation of Commercial Oil

The quality and performance of a base stock Lube oil that is evaluated in G3500 Series Low depends on the source of the crude oil and the Emissions Engines may also be used in G3300, process that is used to produce the base stock. The G3400, and G3500 engines. performance of the base stock can have a significant effect on the performance of the finished lubricant. A Lube oil for G3600 Series Engines must be evaluated responsible oil company closely controls the quality in a G3600 Series Engine. of the base stock by testing the oil in laboratories and in engines. Through careful testing, the oil company Lube oil that is evaluated in G3400 Series or G3300 can identify base stocks that provide similar Series Engines may ONLY be used in G3400 Series performance levels. or G3300 Series Engines. Because of the complex chemistry that is involved Lube oil for GCM34 Series Engine must be evaluated with the evaluation of base stocks, Caterpillar cannot in a GCM34 Series Engine. establish stringent guidelines for the interchanging of base stocks. However, the following characteristics Engine Rating can be used for identifying differences in the performance of base stocks. The average power output that is produced by the engine during the field evaluation is used to establish Viscosity index – The viscosity index of single grade the power rating of the field evaluation. The power oil is an estimate of the base oil composition. Oil that output must be expressed as Brake Mean Effective has a viscosity index that is less than 95 could Pressure (BMEP). The power output is derived from contain a significant amount of napthenic base one of the following sources: stocks. Otherwise, the base stock could have a low level of processing. Napthenic base stocks do not • Output of the generator set provide the same performance as paraffinic base stocks. A finished lubricant must be specially blended • Torque meter in order to use napthenic base stocks. • Output of the gas compressor Oil that has viscosity index of 95 or more contains • Displayed load for the engine paraffinic base stock. If the viscosity index of different shipments of a particular oil increases or decreases In order to calculate the BMEP, the average engine by more the 5, the base stock could have been power output must be expressed in kilowatts. Use the significantly changed. If this occurs, the oil company equation in Table 7 to calculate the BMEP. should be questioned regarding the source and Table 7 quality of the base stock. Equation for Calculating the Brake API base oil classification – The API has divided (BMEP) base stocks into five groups. The groups are identified by the viscosity index and by chemical 120 000 × kW = BMEP (kPa) composition. The different groups provide different L × rpm performance in the finished lubricants. The interchanging of base stocks between those groups kW is the average engine power output during the evaluation. is NOT recommended. The API base stock group cannot be easily detected in the finished lubricant. L is the total displacement of the engine in liters. Therefore, the oil company must inform the customer BMEP is expressed in kilopascals (kPa) about the type of base stock in the finished lubricant. The oil company must also inform the customer if the base stock is changed to a different API base stock Lube oil can be interchanged between engines at group. different sites that operate with a similar duty cycle. However, the interchanging is limited by a maximum of a ten percent increase in BMEP. The oil company must accept the responsibility for the performance of the finished oil. This responsibility Duty cycles can vary greatly between different sites includes the additives and the base stocks. Any and between different engine configurations. significant changes to the composition of the finished Therefore, it is difficult to determine an accurate oil must be reported to the customer in order for the degree of severity for oil in all the various duty cycles. risk to be evaluated. For best results, only use the proven oil in applications with a similar duty cycle. When different Engine Configuration duty cycles are introduced, the risk is increased.

Lube oil cannot be interchanged between engines that use different types of fuel. SEBU6400-06 15 Maintenance Section Synthetic Base Stock Oils

Note: For cases with different duty cycles, the oil i03116076 company and the engine owner will assess the risk in order to determine if another Field Performance Re-refined Base Stock Oils Evaluation is required. In most cases, an oil with proven performance in a particular duty cycle will be SMCS Code: 1300; 1348; 7581 preferred over an oil that has not been proven for that Re-refined basestock oils are acceptable for use in duty cycle. Cat engines IF these oils meet the performance requirements that are specified by Caterpillar. Re- i06579502 refined basestock oils can be used exclusively in finished oil or in a combination with new basestock Synthetic Base Stock Oils oils. The US military specifications and the specifications of other heavy equipment SMCS Code: 1300; 1348; 7581 manufacturers also allow the use of re-refined basestock oils that meet the same criteria. Synthetic base oils are acceptable for use in Cat gas engines if these oils pass the 7000-hour field The process that is used to make re-refined performance test as described in this Special basestock oil should adequately remove all wear Publication. Synthetic oils that are allowed for use in metals that are in the used oil and all additives that Cat gas engines have to meet the SAE 40 grade are in the used oil. Vacuum distillation and the spec. hydrotreating of the used oil are acceptable processes that are used for producing a re-refined Compared to mineral oils, synthetic base oils base oil. generally improve the flow characteristics of oils at low temperatures such as in arctic conditions. Note: Just filtering is inadequate for the production of Synthetic oils also have higher thermal and oxidation re-refined basestock oils from used oil. stability compared to mineral oils. i03116125 Some synthetic base oils have performance characteristics that may enhance the service life of Aftermarket Oil Additives the oil. However, Caterpillar does not recommend the automatic extension of oil drain intervals for any type SMCS Code: 1300; 1348; 7581 of oil. Caterpillar does not recommend the use of Oil drain intervals for Cat engines can only be aftermarket additives in oil. It is not necessary to adjusted after an oil analysis program that contains use aftermarket additives in order to achieve the the following data: maximum service life of the engine or rated performance. Fully formulated, finished oils consist of • Oil condition, oil contamination, and wear metal base oils and of commercial additive packages. analysis (Caterpillar S·O·S Services oil analysis) These additive packages are blended into the base oils at precise percentages in order to help provide • Trend analysis finished oils with performance characteristics that meet industry standards. • Fuel consumption • There are no industry standard tests that evaluate • Oil consumption the performance or the compatibility of aftermarket additives in finished oil. Refer to the “Extended Engine Oil Drains and Warranty” article in the Foreword of this publication. • Aftermarket additives may not be compatible with the finished oil additive package, which could Note: Oils made of synthetic base stocks have to lower the performance of the finished oil. pass the 7000-hour field performance evaluation to be allowed for use in Cat gas engines. • The aftermarket additive could fail to mix with the finished oil. This could produce sludge in the crankcase. In order to achieve the best performance from a Cat engine, conform to the following guidelines: • Select the proper Cat oil or commercial oil that has passed the Field Performance Evaluation. Refer to the “Lubricant Specifications” section of this Special Publication. 16 SEBU6400-06 Maintenance Section Oil Change Interval

• Refer to the “Engine Oil Viscosity” table in this The maximum increment for increasing the oil Special Publication in order to find the correct oil change interval is 250 service hours. This is viscosity grade for your engine. particularly important if a long amount of time is required to obtain results of oil analysis. • At the specified interval, service the engine. Use appropriate new oil and install an appropriate new Illustration 1 is a graphic representation of adjusting oil filter. the oil change interval.

• Perform maintenance at the intervals that are specified in the engine Operation and Maintenance Manual, “Maintenance Interval Schedule”.

i03116161 Oil Change Interval (and Oil Sampling) SMCS Code: 1348 The standard oil change interval for a Cat gas engine is available in the Operation and Maintenance Manual. Consult the Operation and Maintenance Manual for the specific engine model under consideration. In some applications, the oil drain may need to be reduced. Some factors that can reduce an oil drain are fuel type, fuel contamination, operating conditions and environment. In other applications Illustration 1 g01933230 there could be additional life available in the oil. In both cases, the oil drain can be adjusted through the Adjustment of oil change intervals use of S·O·S Services oil analysis. (X) Numbers of oil changes (Y) Service hours In an oil drain optimization program, it is strongly suggested that oil drain extensions be limited to 250 In Illustration 1 , the initial oil change was performed hour intervals. For example, if the standard oil drain after 1000 service hours. The interval was increased is 1000 hours, and the oil appears to have additional in 250 hour increments. At oil change number 8, the life, the first extension should not exceed 1250 hours. oil had reached the condemning limit after 1750 The 1250 hour oil drain interval should be evaluated service hours. Therefore, the interval was reduced to for three service periods, before another extension is 1500 service hours. The results of the oil analysis considered. were acceptable when the oil was used for 1500 service hours. Consult with your Caterpillar S·O·S Services laboratory regarding the adjustment or optimization i06579548 of oil change intervals. Your S·O·S consultant will work with you to develop a plan that provides optimum oil life without compromising engine life of S·O·S Services Oil Analysis durability. SMCS Code: 1000; 1348; 3080; 4070; 4250; 4300; 5095; 7000; 7542; 7581 One of the basic characteristics of an oil evaluation program is consistent oil sampling and frequent oil Caterpillar has developed a maintenance sampling. For Cat gas engines, oil samples should management tool that evaluates oil degradation and be taken every 250 hours. This consistent rate of detects the early signs of wear on internal engine sampling is especially important if an engine is components. The Cat tool for oil analysis is called operating on an inconsistent gas supply. S·O·S Oil Analysis and the tool is part of the S·O·S Services program. S·O·S Oil Analysis divides oil Note: Cooling system problems will also reduce the analysis into four categories: life of engines. S·O·S Coolant Analysis together with S·O·S Oil Analysis provides a complete and accurate • Component wear rate method for monitoring the health of all machine/ engine systems. Refer to the S·O·S Coolant Analysis • Oil condition information in this publication. A properly administered S·O·S Services program will reduce • Oil contamination repair costs and lessen the impact of downtime. SEBU6400-06 17 Maintenance Section S·O·S Services Oil Analysis

• Oil identification Some gaseous fuels may contain significant amounts of corrosive compounds. These corrosive Component wear rate analysis evaluates the wear compounds can form highly corrosive acids in the that is taking place inside the engine. The S·O·S engine oil. The S·O·S Services tests for Oxidation, analyst uses the results of elemental analysis to Nitration, and Viscosity will indicate that these acids evaluate the wear. Trend analysis and proprietary have degraded the oil. In many applications, these wear tables are then used to determine if wear rates tests are sufficient to alert the customer regarding are normal or abnormal. problems with oil deterioration. However, TAN and TBN are recommended in addition to the standard Oil Condition analysis is used in order to determine S·O·S Services tests. if the oil has degraded. Tests are performed in order to look at the oxidation, nitration, and viscosity of the There are two ASTM test methods for the TBN test: oil. The S·O·S analyst uses trend analysis and “D2896” and “D4739”. The “D2896” method is run to proprietary guidelines to determine if the oil has establish the TBN of new oils. “D2896” is best used reached the end of useful life. when sulfur compounds are present. “D2896” does not always show a consistent decrease in base Note: The standard oil analysis should include: number with oil deterioration. The “D4739” method is Oxidation, Nitration, Viscosity, and wear metals at a more effective when monitoring the deterioration of minimum. used engine oils. “D4739” usually shows a consistent decrease in base number, as an oil deteriorates. Oil contamination tests are performed in order to “D4739” responds to sulfuric acids and formic acids. determine if anything harmful has entered the oil. A trained analyst, in the S·O·S Services program, This analysis relies on the results from the following should be utilized to interpret TBN results. The S·O·S tests: elemental analysis, water, and glycol. The analyst understands the correlation of TBN results to: S·O·S Services program has guidelines that are used corrosive wear, oil oxidation, and oil nitration. in order to evaluate the level of contamination in the Another test that is sometimes used to evaluate oil engine oil. condition is Total Acid Number (TAN). The preferred Oil identification is another important part of the method for TAN testing is ASTM “D664”. The TAN test is a measure of the acids that are formed in the S·O·S Oil Analysis program. The wrong oil in an used oil. TAN values will increase as oil deteriorates. engine can severely damage internal components. Like the TBN tests, the TAN test has limitations. The wrong oil can also produce excessive deposits in Sometimes, the TAN test does not measure all of the the combustion chamber. Deposits in the combustion acids that are present in the oil. A trained analyst, in chamber may lead to valve failures, piston ring the S·O·S Services program, should be utilized to scuffing, and a loss of oil control. The S·O·S analyst interpret TAN results. The S·O·S analyst uses elemental analysis and viscosity results to understands the correlation of TAN results to: identify key characteristics of the oils. corrosive wear, oil oxidation, and oil nitration. These four types of analysis are used to monitor the Because of the specialized nature, all S·O·S condition of your engine, and to help you identify Services laboratories may not be equipped to run potential problems. A properly administered S·O·S TBN and TAN tests. If your S·O·S Services lab Services Oil Analysis program helps prevent costly cannot run these tests, your dealership can make damage, reduces repair costs, and reduces arrangements to run these tests at another downtime. laboratory. Note: Obtain each oil sample when the oil is warm TAN and TBN results combined with the normal and mixed. The sample is ensured to be S·O·S data can be helpful in trending the oil condition. representative of the oil in the engine crankcase. Note: S·O·S Services oil analysis for all bio gas Corrosive Gaseous Fuels sites and any site that may have corrosive compounds in the gaseous fuel should include: Corrosive gases may contain high levels of sulfur Oxidation, Nitration, Viscosity, Wear Metal, TAN, compounds, halide compounds, and ammonia and TBN test results. compounds. Your Cat dealer has specific guidelines for these corrosive compounds. Consult your Cat dealer regarding the best methods for measuring and Silicon Containing Gases controlling these compounds in your gaseous fuel supply. Cat gas engines that operate on landfill gases may experience high levels of silicon in the lubricating oil. When these corrosive compounds are present in One possible source of this silicon is from a family of gaseous fuels, perform additional tests on used gas gases called siloxanes. Siloxanes are organic engine oils. These additional tests may also be used compounds composed of silicon, oxygen, and methyl if an oil related issue cannot be resolved through the groups. After combustion, this type of silicon enters standard set of S·O·S Services tests. the oil through the blow-by gasses and the oil film on the cylinder liners. 18 SEBU6400-06 Maintenance Section S·O·S Services Oil Analysis

The silicon compounds from siloxane gases are much less abrasive than silicon compounds found in dirt. Gas engines can operate with silicon levels up to 125 ppm when the source of the silicon is siloxane gases. A trained analyst should be utilized to determine the safe level of silicon and the source of the silicon. Elevated silicon levels caused by dirt entry will severely damage internal engine components. Refer to the Special Publication, LEBW4977, “Gaseous Fuels - Application and Installation Guide” for more information on siloxane gases and other contaminants. S·O·S Services Oil Analysis Guidelines A trained analyst, at your Cat dealership, interprets the results of these oil analysis tests. S·O·S Services oil interpretation is built on a system of trend analysis, correlating data, and historical guidelines. The S·O·S Services analyst understands the interactions of each test. Analysts use this information to make an accurate interpretation of the oil analysis test results. The table below lists the guidelines that are used to evaluate used engine oils. Table 8 Oil Analysis Guidelines for non-corrosive(1), low silicon(1) , gaseous fuels

Test Parameter S·O·S Services Oil Analysis General Oil Analysis

Water 0.5% Maximum 0.5% Maximum

Glycol 0.1% Maximum 0.1% Maximum

+3 centistoke (cSt) change from new oil +3 centistoke (cSt) change from new oil Viscosity “ASTM D445”, at 100° C (212° F) viscosity viscosity

Trend Analysis and statistical limits estab- Elemental Analysis Cat statistical norms and trend analysis(2) lished by the testing laboratory(3)

Caterpillar SOS uses the UFM method for 0.25 absorbance / cm-1 based on “ASTM Oxidation measuring Oxidation. The general guideline is D7418” differential scan method, and trend 30 UFM for condemning the oil.(4) analysis

0.25 absorbance / cm-1 based on “ASTM Nitration Cat guidelines and trend analysis D7418” differential scan method, and trend analysis

Additional Oil Analysis Guidelines for corrosive(1) , high silicon(1) , gaseous fuels

3.0 maximum or 2.0 greater TAN than the new 3.0 maximum or 2.0 greater TAN than the new Total Acid Number (TAN) by “ASTM D664” oil oil

Total Base Number (TBN) by “ASTM D2896” 50% of new oil TBN 50% of new oil TBN (1) Consult your Cat dealer for specific guidelines regarding sulfur compounds, halide compounds, ammonia compounds, and silicon com- pounds found in corrosive gaseous fuels. (2) A trend can be established from the results of three oil analyses. (3) Consult with your independent laboratory regarding guidelines for elemental analysis. (4) UFM is the Caterpillar proprietary method for measuring oxidation. SEBU6400-06 19 Maintenance Section S·O·S Services Oil Analysis

Note: The Caterpillar un-subtracted FTIR method (UFM) is a replacement of the current Caterpillar Percent Allowable differential method. In the UFM method the oxidation of the oil is calculated using the test oil ( the "neat" used oil) FTIR spectrum without any subtraction of the new oil reference spectrum. During Caterpillar's development of this test method, it was revealed that reference oils were the major source of failures with the current Percent Allowable differential method. The new Un-subtracted FTIR method removes the dependence on a reference oil, therefore eliminating the majority of the failures.

Note: Most oil analysis programs do not detect larger particles in the oil sample. Some failure modes only produce larger particles. Oil analysis alone will not always detect an impending failure. Oil filters should be sectioned and inspected for the presence of visible particles. Trend Analysis

Illustration 2 is an example of a graph for the trends of wear metal analysis and of infrared analysis. 20 SEBU6400-06 Maintenance Section Hydraulic Oil

Illustration 2 g01934716

The analysis of the wear metals in Illustration 2 Caterpillar has developed a new class of hydraulic shows typical normal levels. However, the level of oils, the HYDO Advanced fluids. These new nitration has exceeded the acceptable limit. The advanced fluids are designed for optimal oxidation is also increasing. In conclusion, this performance in new advanced hydraulic systems that analysis indicates that the engine oil must be are designed with close tolerances for precise replaced. operation and that operate under demanding conditions of temperatures and pressures. These In the absence of analysis, change the engine oil fluids ensure optimal performance in current and according to the engine Operation and Maintenance previous hydraulic systems. Four new products have Manual, “Maintenance Interval Schedule”. been introduced:

i06560384 • HYDO Advanced 10 , SAE 10W Hydraulic Oil • HYDO Advanced 20 , SAE 20W SMCS Code: 1348; 4250; 5050; 5095; 7581 • HYDO Advanced 30 , SAE 30 Applications

• Hydraulic systems • Hydrostatic transmissions SEBU6400-06 21 Maintenance Section Hydraulic Oil

• Bio HYDO Advanced , Multigrade If a different viscosity is required due to ambient temperatures, the following Caterpillar oils can be Cat HYDO Advanced Hydraulic used: Oils, SAE 10W, SAE 20W, and SAE • Cat DEO-ULS and Cat DEO 30 • Cat DEO-ULS SYN and Cat DEO SYN Cat HYDO Advanced hydraulic oils are designed to • Cat DEO Cold Weather provide extended oil drain intervals and to provide extra protection to Cat hydraulic system components • Cat TDTO and hydrostatic transmissions. • Cat TDTO Cold Weather Cat HYDO Advanced hydraulic oils are formulated of premium additives and premium base stocks that • Cat TDTO-TMS pass severe qualification testing requirements, in the field and in the laboratory, to provide superior • Cat MTO protection for Cat hydraulic systems. Note: Caterpillar oil availability will vary by region. Cat HYDO Advanced hydraulic oils are preferred in most hydraulic systems and in most hydrostatic Note: Oil drain intervals of the oils listed above are systems. Refer to this Special Publication, Lubricant less than the intervals of Cat HYDO Advanced oils. Viscosities, Table Hydraulic Systems Lubricant The oil drain intervals of these oils are typically 2000 Viscosities for Ambient Temperatures for the ambient hours and up to a maximum of 4000 hours. An operating temperatures for Cat HYDO Advanced exception is Cat TDTO Cold-Weather oil which hydraulic oils. allows 6000 hours or higher oil drain interval. SOS Cat HYDO Advanced oils allow 6000 hours or higher Services Oil Analysis is required when the oils listed oil drain intervals for most applications. S.O.S above are used in Cat hydraulic system components Services oil analysis is recommended when the oil and hydrostatic transmissions. drain interval is increased to 6000 hours or higher. In comparison, non-Cat commercial hydraulic oils For applications requiring the use of fire-resistant (second choice oils) allow 2000 hours oil drain hydraulic fluids, Caterpillar recommends the use of interval. Follow the maintenance interval schedule for EcoSafe FR-46. This product is a fully synthetic, oil filter changes and for oil sampling that is stated in nonaqueous . Water based and glycol- the Operation and Maintenance Manual for the based hydraulic products are not recommended for particular machine. Consult your Cat dealer for use in Cat machine hydraulic systems. EcoSafe FR- details. 46 is an ISO 46 multi-grade product. For more information refer to the product information provided Cat HYDO Advanced hydraulic oils offer the following by the manufacturer of EcoSafe hydraulic oil. Refer benefits: to your Cat dealer for availability. • Enhanced anti-wear protection : protects wear surfaces and reduces component wear in various Cat Bio HYDO Advanced hydraulic pumps (Hydraulic Oil)

• Protection against rusting and corrosive wear Cat Bio HYDO Advanced is biodegradable non-toxic hydraulic oil that is recommended for use in hydraulic • Dispersion of water prevents pump damage due to systems when environmental compliance is required water ingestion and prevents system damage due or desired. Cat Bio HYDO Advanced has a to freezing of water renewable content that exceeds 90% and complies with the European Eco-Label. Consult Federal, state, • 250% increase in oxidation stability per ASTM or local authorities for guidance on hydraulic oils D943 environmental requirements in your area. • Rapid air release protects against cavitation Cat Bio HYDO Advanced is formulated with premium additives and synthetic biodegradable base oil that • Improved filtration properties helps support pass severe qualification testing requirements to component cleanliness provide superior protection for Cat hydraulic systems and hydrostatic transmissions. Cat HYDO Advanced oils, when switching to Cat HYDO Advanced oils, cross contamination with the previous hydraulic oil should be kept to less than 10%. 22 SEBU6400-06 Maintenance Section Hydraulic Oil

Cat Bio HYDO Advanced oils allow 6000 hours or higher oil drain intervals for most applications. S.O.S NOTICE Services oil analysis is recommended when the oil Cat does not warrant the quality or performance of drain interval is increased to 6000 hours or higher. In non-Cat fluids. comparison, non-Cat commercial biodegradable The minimum viscosity for commercial alternative oils hydraulic oils (second choice oils) allow a maximum used in most Caterpillar machine hydraulic systems of 2000 hours oil drain interval. Follow the maintenance interval schedule for oil filter changes and in most Cat hydrostatic transmission systems is and for oil sampling that is stated in the Operation 6.6 cSt at 100° C (212° F) per ASTM D445. and Maintenance Manual for your particular machine. If Caterpillar oils cannot be used, oils meeting the Consult your Cat dealer for details. following commercial specifications can be used in Cat Bio HYDO Advanced performs similar to Cat most Cat hydraulic systems and in most Cat HYDO Advanced 10 and offers the following benefits: hydrostatic transmission systems: superior protection against mechanical wear, foaming, and corrosion in hydraulic systems and in • Engine oils that meet the Cat ECF-1-a, Cat ECF- hydrostatic transmissions. This oil should be used to 2, or Cat ECF-3 specifications and have a achieve maximum life and maximum performance minimum zinc additive of 0.09 percent (900 ppm) from hydraulic system components and from hydrostatic transmissions. Cat Bio HYDO Advanced • Biodegradable oils that meet the Cat BF-2 is preferred in most hydraulic systems and in most specification hydrostatic systems when ambient temperature is between −30° C (−22° F) and 45° C (113° F). • TO-4 specification oils that have a minimum zinc Consult your Cat dealer for details. additive of 0.09 percent (900 ppm) To gain the most benefit from the improved Note: Industrial hydraulic oils are not recommended performance designed into Cat Bio HYDO Advanced for service fill-in Caterpillar hydraulic systems. oils, when switching to Cat Bio HYDO Advanced oils, Commercial Biodegradable Hydraulic Oil. cross contamination with the previous hydraulic oil should be kept to less than 3%. Flushing of the Note: Non-Cat commercial oils that are acceptable hydraulic system is recommended to reduce the for use in most Cat hydraulic and hydrostatic cross contamination. Cat Bio HYDO Advanced can transmission systems are as a group third choice be used in hydraulic systems of other Original oils. Equipment Manufacturers (OEM). Refer to your manufacturer requirements for application details. Within this grouping of third choice oils there are tiered levels of performance. Commercial oils that meet the Cat BF-2 specification should be used. Note: Oil meeting the Cat BF-2 specification should only be used in hydraulic systems where recommended.

NOTICE Cat does not warrant the quality or performance of non-Cat fluids. If Cat oils cannot be used, commercial biodegradable hydraulic oils that meet the Cat BF-2 Performance Requirements should be used. Cat BF- 2 replaces Cat BF-1 Performance Requirements. Cat BF-1 Performance Requirements are obsolete.

Illustration 3 g00103844 NOTICE Do not use commercial oils that meet the BF-2 speci- Machines with this symbol are filled with fication in compartments containing friction material biodegradable hydraulic oil. This symbol is on the except Hydraulic Excavators. Refer to the machine hydraulic tank. Operation and Maintenance Manual or consult your local Cat dealer for guidance before using commer- Commercial Oils cial oils that meet the BF-2 specification in Hydraulic Excavators. Note: Non-Caterpillar commercial oils that are acceptable for use in most Cat hydraulic and hydrostatic transmission systems are as a group third choice oils. Within this grouping of third choice oils there are tiered levels of performance. SEBU6400-06 23 Maintenance Section Lubricating Grease

Biodegradable hydraulic oils are formulated with the Some work sites require the use of a single grease to following components: a saturated Hydraulic fulfill the needs of all the equipment. Always choose a Environmental Ester Synthetic (HEES), synthetic grease that meets or exceeds the requirements of base stock, and selected additives. Consult Federal, the most demanding application. Remember that state, or local authorities for guidance on hydraulic oil commercial products which barely meet the minimum environmental requirements in your area. performance requirements can be expected to produce the minimum life for the parts. It is not i06579723 recommended to purchase grease products based on the lowest cost as the only consideration. Instead, use the grease that yields the lowest total operating Lubricating Grease cost. This cost should be based on an analysis that SMCS Code: 1000; 7581 includes the improved product life, costs of parts, labor, downtime, and the cost of the amount of grease that is required. NOTICE These recommendations are subject to change with- Note: Certain Cat grease products are formulated out notice. Consult your local Cat dealer for the most with Molybdenum disulfide (MoS2 or “Moly”). The up to date recommendations. Moly used in Cat greases is of a technical fine grade. This size meets the special requirements of some rolling element bearings, joints, and other moving Note: Non-Cat commercial greases are as a group components of tight clearances. second choice greases. Within this grouping of second choice greases there are tiered levels of Note: When the grease in a joint is changed from performance. one type of grease to another or a grease from a different supplier is to be used, the general NOTICE recommendation is to purge all the old grease from Cat does not warrant the quality or performance of the joint. Some greases are not chemically non-Cat fluids and greases. compatible. Consult your supplier to determine if the greases are compatible. Caterpillar provides a family of grease products that vary in performance from moderate to high If in doubt, Purge! performance. These greases services the entire line of Cat products in the wide variety of climates Note: All Cat greases are “chemically” throughout the world. From this variety of Cat grease compatible with each other. Mixing of Cat products, you can find a Cat grease that will meet or greases will not result in an adverse chemical exceed the performance requirements for almost reaction. However, mixing of Cat greases might every machine that is produced by any Original result in reduced performance. Equipment Manufacturer (OEM), and for almost every machine application or equipment application. Moderate Applications Before selecting a grease product, the performance requirements must be determined. Consult the The Caterpillar family of greases includes several grease recommendations in your Operation and which are formulated for moderate applications of Maintenance Manual. Also, consult your Cat dealer medium loads and speeds. These greases are for a list of greases that have the performance formulated to provide optimal performance for these specifications and the available container sizes. applications. This grease chapter refers to NLGI of the grease products offered by Caterpillar. The National Cat Utility Grease Lubricating Grease Institute (NLGI) classifies the greases per the consistency or hardness according Cat Utility Grease is formulated for use in to “ASTM D4950” and “SAE J310”. The higher the applications that have a low severity to a medium NLGI value the more firm the grease. NLGI is an severity and moderate temperatures. Cat Utility important classification for greases and it should be Grease is a National Lubricating Grease Institute used along with other properties such as stability, (NLGI) grade 2 grease. This grease is made with corrosion resistance, and viscosity. petroleum base oil and a lithium complex thickener.

Note: Always choose grease that meets or exceeds the recommendations that are specified by the equipment manufacturer for the application. 24 SEBU6400-06 Maintenance Section Lubricating Grease

Note: If the application calls for a utility grease and Note: If the application calls for a multipurpose Cat Utility Grease is not available, consult the grease grease with molybdenum and Cat Prime Application data sheets. Use a substitute that meets or exceeds Grease is not available, consult the data sheets for the performance characteristics of Cat Utility Grease. the greases. Use a substitute that meets or exceeds the performance characteristics of Cat Prime Cat White Assembly Grease Application Grease.

Cat White Assembly Grease is formulated for use in Severe Applications applications that have low to medium severity and moderate temperatures. This grease has been made The Caterpillar family of greases includes several extra tacky to hold , O-rings, and needle which are made with a Calcium Sulfonate Complex bearings to aid in the assembly of engines, thickener. This type of grease is ideal for severe transmissions, and other components. Cat White applications. These greases provide more load Assembly Grease is an NLGI grade 2 grease. This carrying (galling resistance), lower wear, longer grease is made with a petroleum base oil and a working life, exceptional water washout, and lithium complex thickener. resistance to corrosion. Cat Prime Application Grease Hammer Grease

Cat Prime Application Grease is formulated for use in Note: Refer to the Operation and Maintenance applications with low severity to high severity at Manual for a particular hammer for recommendations moderate temperatures. Cat Prime Application that relate to greases for Cat Hammers. Grease is recommended for heavily loaded pin joints and high impact applications in machines such as track-type tractors, backhoe loaders and skid steer Cat Extreme Application Grease loaders. Cat Extreme Application Greases are specially Cat Prime Application Grease is an NLGI grade 2 formulated to protect all the most heavily loaded grease. This grease is made with petroleum base oil joints in any Cat machine against galling, wear, and and a lithium complex thickener. This grease has 3% corrosion. This protection is sustained while Molybdenum Disulfide (MoS2 or “Moly”). operating in moderate temperatures and with wet or dry working conditions. Cat Extreme Application Greases are available in NLGI grades, 1, and 2. Cat Extreme Application Greases are made with special blends of petroleum base oils and Calcium Sulfonate Complex thickener. These greases also have 5% Molybdenum Disulfide

(MoS2 or “Moly”) and performance enhancing additives. A significant challenge exists in order to get grease to pump into the joints at low temperatures. Once the grease gets to the joint, the grease must have high resistance to galling, wear, fretting, water washout, and corrosion in order to protect highly loaded joints adequately. Cat Extreme Application Greases are formulated with special blends of naphthenic petroleum base oils that have low pour points and will pump at lower temperatures. The ability to pump Cat Extreme Application Greases at lower temperatures means added insurance that all of the grease joints in the machine will be adequately lubricated even if the ambient temperature drops unexpectedly. Even under severely loaded conditions, the grease should have a long working life. In order to make greases that meet these greater demands, a Calcium Sulfonate Complex thickener with a properly blended naphthenic oil and/or a synthetic base oil is preferred. Caterpillar uses these ingredients in Cat Extreme Application Greases. SEBU6400-06 25 Maintenance Section Lubricating Grease

Cat Extreme Application Greases also have 5% Moly, Cat Extreme Application Grease-Desert is made to instead of the 0% to 3% that is found in most other be extra tacky. In some applications, the film of greases. This additional Moly greatly improves the grease must adhere to vertical surfaces. An example ability of the grease to protect parts from damage in of this application is swing gears for excavators. applications with severe impact (slamming). Many conventional greases do not have enough of the tackifier to allow the grease to stay in place Cat Extreme Application Greases are also made to resulting in incomplete lubrication and premature be extra tacky. In some applications, the film of wear or failure of components. In addition, many of grease must adhere to vertical surfaces. An example these conventional greases do not have the of this application is swing gears for excavators. performance, particularly at high ambient Many conventional greases do not have enough of temperatures, to protect the gear teeth in these the tacky characteristic to keep the grease in place applications. resulting in incomplete lubrication and premature wear or failure of components. Cat Extreme Application Grease-Desert prevents galling and wear in hot temperatures under severe Note: If the application calls for Cat Extreme loads and conditions. In moderate temperatures, Cat Application Grease and Cat Extreme Application Extreme Application Grease-Desert can be used in Grease is not available, consult the data sheets for severe applications if an improvement over Cat the grease. From these data sheets, use a substitute Extreme Application Grease is desired. Cat Extreme that meets the performance characteristics of Cat Application Grease-Desert can be used in Extreme Application Grease. applications that require the lubricant to last for long periods of time because this grease has an high Cat Extreme Application Grease- performance and long life. Desert Note: If the application calls for Cat Extreme Application Grease-Desert and Cat Extreme Cat Extreme Application Grease-Desert is formulated Application Grease-Desert is not available, consult to protect the most severely loaded joints in Cat the data sheets for the grease. From these data machines against galling, wear, and corrosion. This sheets, use a substitute that meets the performance protection is sustained while working in moderate to characteristics of Cat Extreme Application Grease- hot temperatures with wet or dry conditions. Desert. Cat Extreme Application Grease-Desert is an NLGI grade 2 grease. This grease is made with petroleum Cat Extreme Application Grease- that has a high viscosity and a Calcium Sulfonate Arctic (Semi-Synthetic) Complex thickener. This grease also has 5%

Molybdenum Disulfide (MoS2 or “Moly”) and tackifier. Cat Extreme Application Grease-Arctic is formulated As the temperature changes, Cat Extreme to protect the most heavily loaded joints in Caterpillar Application Grease-Desert experiences minimal machines against galling, wear, and corrosion. This change in viscosity and will maintain a thick lubricant grease resists breakdown even under heavy loads film even at hot temperatures. and/or in applications with frequent oscillations. This grease provides protection that will be sustained for Cat Extreme Application Grease-Desert is made with long periods of time and in wet or dry conditions. This a Calcium Sulfonate Complex thickener. Cat Extreme protection is sustained, while work is being done in Application Grease-Desert provides the necessary moderate temperatures and in low temperatures that protection against galling, wear, fretting, water may reach −50° C (−58° F). In moderate washout, and corrosion. Cat Extreme Application temperatures, Cat Extreme Application Grease-Arctic Grease-Desert also has a long life. This grease will can be used in the application if the compartment is resist breakdown even when the application is under sealed tightly to contain the grease heavy loads and with frequent oscillations. This protection is sustained while work is being done at Cat Extreme Application Grease-Arctic is available in moderate to hot temperatures under wet or dry NLGI grade 0.5. This grease is made with a semi- conditions. synthetic base oil that has a low viscosity for optimal cold-weather performance. The performance is Cat Extreme Application Grease-Desert has 5% enhanced with 5% Molybdenum Disulfide (MoS2 or molybdenum instead of the 0% to 3% that is found in “Moly”) and tackifier. most other greases. This additional molybdenum greatly improves the ability of the grease to protect parts from damage in applications with severe impact (slamming). 26 SEBU6400-06 Maintenance Section Lubricating Grease

Because the base oil is semi-synthetic, Cat Extreme Pumpability is based on “USS Mobility and Lincoln Application Grease has a minimal change in viscosity Ventmeter Tests”. Performance may vary depending as the temperatures drop. Because the synthetic on lubrication equipment and the length of the lines. base oil has a low viscosity, the Cat Extreme Application Grease-Arctic has a minimal change in Service Life refers to the percent of change after viscosity and continues to flow easily as the 100,000 strokes in technical data sheet (“ASTM D temperature drops. Cat Extreme Application Grease- 217”). Arctic pumps easily at low temperatures. In fact, Cat Extreme Application Grease-Arctic NLGI grade 0.5 Corrosion protection was measured per “ASTM can be pumped through standard automatic D1743 Rust preventative Properties” and “ASTM lubrication systems that are machine mounted and at D4048 Copper Corrosion Test”. temperatures down to −50° C (−58° F). This means that the grease can be pumped through long Water washout resistance refers to roll stability with unheated lines and into the required joints. water and the percent of change (“ASTM D 1264”). Cat Extreme Application Grease-Arctic has 5% of For additional performance data on these greases molybdenum instead of 0% or 3% that is found in refer to this Special Publication, “Reference Material” most of the other greases. This additional article. molybdenum greatly improves the ability of the grease in order to protect parts from damage in applications with severe impact (slamming). Cat Extreme Application Grease-Arctic is made to be extra tacky. In some applications, the film of grease must adhere to the vertical surfaces. An example of this application is swing gears for excavators. Many conventional greases do not have enough tackifier to adhere well to the vertical surfaces. This ability is necessary in order to protect the gear teeth in these applications adequately. Cat Extreme Application Grease-Arctic may be used in applications that require the lubricant to last for long periods of time. This grease has an high performance and also has a long life. If the application calls for Cat Extreme Application Grease-Arctic and no Cat Extreme Application Grease-Arctic is available, consult the data sheets for the grease. Use a substitute that most closely meets the performance characteristics. Cat Ball Bearing Grease

This grease is recommended for applications that utilize roller bearings and ball bearings at low loads to moderate loads at high speed. Typical applications for this grease are electric motors, alternators, and constant velocity (CV) joints for automotive products. Cat Ball Bearing Grease is an NLGI grade 2 grease. This grease is made with petroleum base oil and polyurea thickener. Grease Application Charts

Types of Grease

Severe Applications are heavy loads, frequent oscillations, and heavy shock loads. Extreme pressure (EP) refers to 4-Ball Weld point in the technical data sheet (“ASTM D 2596”). N/R = Not Recommended SEBU6400-06 27 Maintenance Section Lubricating Grease

Table 9 Type of Cat Grease

Low Temp. Corrosion Water Washout Extreme Pres- Cat Grease Name NLGI Grade Service Life Pumpability Protection Resistance sure (EP)

Cat Extreme Appli- cation Grease- 2 above 2° C (35° F) Excellent Excellent Excellent Excellent Desert

Cat Extreme Appli- above −7° C 2 Excellent Excellent Excellent Excellent cation Grease (20° F)

Cat Extreme Appli- above −18° C 1 Excellent Excellent Excellent Excellent cation Grease (0° F)

Cat Extreme Appli- above −43° C cation Grease- 0 (−45° F) Excellent Excellent Excellent Excellent Arctic

Cat Prime Applica- above −18° C 2 Good Fair Fair Very Good tion Grease (0° F) above −23° C Cat Utility Grease 2 (−10° F) Good Fair Fair Fair

Cat Ball Bearing above −18° C 2 Very Good Good Good N/R Grease (0° F)

Hammer Paste 2 N/R Good Fair Fair Excellent

Table 10 Types of Cat Grease

Severe Applica- Cat Grease NLGI Severe Severe Severe tions with Ex- Severe Name Grade Applications Applications Applications tremely Heavy Applications Loads

Operating Extremely low to Low to Moderate Moderate to high Moderate to high High to extremely - Conditions low temperatures Temperatures temperatures temperatures high temperatures

Optimum Tem- −50° C (−58° F) to −23° C (−9° F) to 18° C (64° F) to 18° C (64° F) to 38° C (100° F) to - perature Range −18° C (0° F) 29° C (85° F) 60° C (140° F) 41° C (105° F) 232° C (450° F)

Cat Extreme Ap- plication 2 N/R Excellent Excellent Excellent Very good Grease-Desert Cat Extreme Ap- 2 N/R Excellent Excellent Very good Good plication Grease

Cat Extreme Ap- 1 Good Excellent Good Good plication Grease

Cat Extreme Ap- plication 0 Excellent Very good N/R N/R N/R Grease-Artic Cat Prime Appli- 2 N/R Fair Good Good N/R cation Grease Cat Utility 2 N/R N/R N/R N/R N/R Grease Cat Ball Bearing 2 N/R N/R N/R N/R N/R Grease Hammer Paste 2 N/R N/R Excellent Excellent Excellent 28 SEBU6400-06 Maintenance Section Fuel Specifications

Fuel Specifications Cat gas engines will operate successfully on a broad range of gaseous fuels. Adjustments must be made to the fuel system when the engine is commissioned i03127807 or when the fuel is changed. Consult your Caterpillar dealer about the proper adjustments. General Fuel Information Permissible fuels must be analyzed in order to SMCS Code: 1250; 1280 determine the following characteristics: • Composition NOTICE Every attempt is made to provide accurate, up to date • Contaminants information. By use of this document you agree that Caterpillar Inc. is not responsible for errors or • Heat value omissions. Follow all applicable industry standards. Follow all • Methane number applicable governmental and environmental safety • Specific gravity guidelines, practices, regulations, and mandates. Field gas can have varying characteristics of The information that is provided is the latest combustion. Field gas can contain numerous harmful recommendations for the Cat gas engines that are impurities. The impurities can alter the BTU value. covered by this Special Publication. This information The impurities can also alter the methane number. supersedes all previous recommendations which The impurities include everything from water up to have been published for the Cat gas engines that are complex hydrocarbons that can lead to detonation covered by this Special Publication. Special fluids are and severe engine damage. In order to minimize required for some engines and it will be necessary to these effects, Caterpillar recommends the following continue to use these special products. Refer to the guidelines: applicable Operation and Maintenance Manual. • Evaluate the fuel with the most current revision This publication is a supplement to the Operation and Maintenance Manual. This publication does not level of Caterpillar Methane Number Program, replace the engine specific Operation and LEKQ6378. Maintenance Manuals. • Methane values below 30 are not recommended for use in a Cat engine. Fuels with a methane NOTICE These recommendations are subject to change with- number that is below 30 must first be processed in out notice. Consult your local Cat dealer for the most order to remove harmful impurities in the fuel and up to date recommendations. raising the methane number into the acceptable range. • If necessary, use an engine that is configured for a NOTICE Caterpillar does not warrant the quality or perform- fuel that has a high energy. Consult the ance of non-Caterpillar fluids and filters. appropriate manual for the engine in order to determine the recommended engine timing.

• Reduce the oil change interval according to the NOTICE Refer to the engine Operation and Maintenance results of the oil analysis. Manual for any fuel information that may be spe- Before the engine arrangement is ordered, use the cific to that application. methane number in order to determine the following characteristics for the new engine: Gaseous fuels consist primarily of hydrocarbons (combinations of hydrogen and carbon) and some • inert gases. Pipeline natural gas has been used for many years. Other types of fuels such as wellhead • Fuel system components gas, bio-gas, and manufactured gas need to be • reviewed for acceptability. • Rated load Each commercial fuel gas is a mixture of gases. Some of the gases are combustible and some of the For a detailed explanation of methane numbers, refer gases are inert. The compositions of these gas to the most current revision level of Special mixtures have extreme variations. Publication, LEBW4977, “Gaseous Fuels - Application and Installation Guide”. SEBU6400-06 29 Maintenance Section Fuel Effects on Maintenance Costs

The High Heat Value (HHV) is a measurement of the The engine must be properly equipped for the use of total heat that is generated by combustion of a fuel. propane. The use of pistons with a low compression When any hydrocarbon is used as a fuel in an ratio and a derating is required. internal combustion engine, water is one of the products of combustion. The water is converted into HD-5 propane has a Low Heat Value (LHV) between steam before leaving the engine. The conversion 2427 to 2532 kJ/0.305 m3 (2300 to 2400 Btu/ft3). Due requires heat. The steam removes the heat and the to the higher heat of combustion that is produced by energy is not used by the engine. The HHV minus the propane, engines that use this fuel will have higher heat that is used to vaporize the water equals the exhaust port temperatures than engines that use dry Low Heat Value (LHV) of the fuel. The LHV is natural gas. sometimes known as the fuel energy content. Generally, fuel with a lower LHV releases heat less The higher exhaust temperatures tend to reduce the rapidly. service life of the cylinder head, of the , and of the turbocharger.

i03615747 i03615900 Fuel Effects on Maintenance Wellhead Gas Costs SMCS Code: 1280-G6 SMCS Code: 1280 Wellhead gas (field gas) is a mixture of hydrocarbons There are many sources of the fuel that is used in and inert gases that is drawn directly from the gas engines. These different sources may have an wellhead in the gas field. Wellhead gas has minimal effect on the engine maintenance intervals. These processing before entering the fuel manifold. This sources include pipeline natural gas, wellhead gas, fuel is commonly used in engines that power gas bio-gas, and propane. compressors. With pipeline natural gas, maintenance intervals The composition of gas from the wellheads in might be extended. Due to the harmful effects of different gas fields varies, and the composition of the impurities that contaminate gases such as bio-gas, gas from different wellheads within the same gas shorter maintenance intervals would be expected. field can vary. Different compositions have different These maintenance intervals can be improved by characteristics of combustion. As a result, the gas processing the gas in order to remove damaging from one source may be acceptable for use but the impurities. gas from a different source may not be acceptable. Heavier hydrocarbons such as pentane and butane For more information on types of fuels, refer to the can cause detonation and other problems. For these appropriate topics in this Special Publication, “Fuel reasons, a fuel analysis is required to determine if the Specifications” section. For specific information on fuel is acceptable for a particular Cat engine. the maintenance intervals, refer to the Operation and Maintenance Manual for the engine. Note: The composition of the gas from a field can change over time. Allow some adaptability for this i03615781 change during the life of the project. Some gas fields contain significant amounts of Propane hydrogen sulfide. In these cases, follow the SMCS Code: 1280 precautions that are recommended in this Special Publication, “Sour Gas” topic. NOTICE The site may have equipment such as scrubbers, Propane and blends of propane may cause detona- liquid separators, and heat exchangers that remove tion in high compression engines. Propane fuel water and liquid hydrocarbons from the gas. should never be used with G3600 engines. However, vapor can still be drawn into the engine. The maintenance costs are variable for engines that Propane is transported to a site as a liquid. The liquid use wellhead gas. Sometimes, overhauls are needed is converted into a gas at the site. at intervals that are sooner than the expected time. However, the practices and factors at many sites For the guidelines in this Special Publication, enable overhaul intervals that are longer than the propane must meet these HD-5 specifications (“Gas expected times: efficient preventive maintenance, Processors Association, GPA Standard 2140-97, Liquefied Petroleum Gas Specifications and Test proper engine oil, and operation below the rated load. Methods”): Follow the guide for fuel usage that is in the Engine • 95 percent propane Performance publication. These publications are available from your Caterpillar dealer. • Remaining 5 percent is not heavier than butane. 30 SEBU6400-06 Maintenance Section Sour Gas

Consult your Caterpillar dealer before operating the i03127811 engine with fuel that has hydrocarbons that are heavier than butane. Bio-Gas Note: Use the Cat Methane Program, LEKQ6378 SMCS Code: 1280-G5 to determine if the fuel is suitable for the particular engine application. Bio-gas is generally classified as gas that is obtained from these sources:

i03127810 • Landfills Sour Gas • Facilities that produce digester gas SMCS Code: 1280 Although these gases are both the result of organic decomposition, the compositions are different. Many gaseous fuels contain sulfur compounds. These compounds are primarily composed of hydrogen sulfide (H2S). Gaseous fuels with more Landfill Gas than 0.43 mg H2S/MJ (.45 µg H2S/Btu) or above 10 ppm are considered to be sour gas. The following The decomposition of organic material produces gases are within this category: landfill gas. The composition of landfill gas depends on the materials that are in the landfill. The gas is • Some wellhead gases collected through a grid of pipes that are laid out within the landfill. • Landfill gas Landfill gas may contain contaminants that can • Digester gas cause harmful effects on engines: Required maintenance is increased by the • Chlorine introduction of hydrogen sulfide into the fuel. For sour gas, Caterpillar recommends engine arrangements • Fluorine for landfill gas. • Siloxanes The use of gases that have hydrogen sulfide can damage the engine. Products of combustion (water • Sulfur vapor and sulfur oxides) form sulfurous acid and sulfuric acid. • Water vapor Analyze the gas before use. If the gas has more than Fuel analysis is required in order to provide guidelines for treatment of the fuel. 0.43 mg of H2S/MJ (.450 µg of H2S/Btu), treat the gas in order to reduce the content of hydrogen sulfide. For more information, see this Special The sulfur compounds in landfill gas cause the same Publication, “Hydrogen Sulfide Effects on Engine engine problems as sulfur in sour gas. When landfill Maintenance Costs”. gas is used, follow the precautions that are recommended for sour gas. i03616061 Landfills can also contain chlorine and fluorine compounds in the form of volatile organic compounds Dry Natural Gas and chlorofluorocarbons. When these substances are burned in engines, corrosive hydrochloric acid (Pipeline) and hydrofluoric acid can be produced. SMCS Code: 1280-G6 Landfill gas can corrode both the equipment that handles the gas and the engine. Vapor is produced Dry natural gas is a mixture of methane and traces of by combustion. If that vapor condenses in the heavier hydrocarbons. Dry natural gas has been crankcase, a solution that is potentially corrosive to processed in order to remove liquids. This gas has a the engine can form. low tendency to detonate. Landfill gas and digester gas can contain siloxanes. For dry natural gas, the acceptable limit of hydrogen Siloxanes are formed when silica ions attach to the sulfide is 0.43 mg/MJ (0.45 µg/Btu). methane hydrocarbon chain. These gaseous compounds enter the combustion chamber with the The heat value of dry natural gases may vary. This fuel. This creates deposits in the cylinders. depends on the composition of the gas. Dry natural gas usually has an LHV that is between 33.53 to 34.65 kJ/L (900 to 930 Btu/cu ft). Cat Gas Engines are adjusted at the factory with a dry natural gas that is within this range. SEBU6400-06 31 Maintenance Section Bio-Gas

In addition, calcium from engine oils contributes to During normal combustion, some exhaust gas is deposits. Hence, deposits in the combustion forced past the piston rings and into the crankcase. chamber are generally a combination of these The contaminants in this blowby are vented away materials: silicon, calcium and some traces of other from the crankcase by positive crankcase ventilation. elements. The contaminants are diluted and purged. Siloxane particles can be abrasive to exhaust valve The formation of water in the crankcase and in the faces and to valve seats. This causes the valves to valve mechanisms can result in an acid solution become pitted and indented. The particles can also which allows corrosion to occur. A high jacket water build up on the valve seat. The buildup can cause coolant temperature helps to prevent the guttering of the valves. condensation of water in the crankcase. Engines that are used for landfill gas have a high temperature Deposits also form on the pistons and on the bottom jacket system as standard equipment. deck of the cylinder heads. These deposits can increase the compression ratio, which can lead to In order to protect the service life of the engine, it is detonation and/or preignition. Detonation and/or necessary to follow the guidelines for operation and preignition can loosen the deposits. The deposits that maintenance that are recommended by Caterpillar. are loosened can be trapped between the valve and Engines operating on Landfill gas need to a have the valve seat. The valve will be held open. Guttering positive crankcase ventilation system to help of the valve will result. decrease acid formations. Landfill gas also requires regular, careful maintenance of the spark plugs. The formation of deposits depends on the following Misfire causes the engine to run rough and the factors: cylinder temperatures are reduced. Cooler cylinders • Composition of the fuel allow deposits to build up faster in the combustion chamber, in the exhaust manifold, and in the turbocharger. Exhaust port temperatures can indicate • Operating conditions the performance of the spark plugs. An exhaust port • Type of lubrication oil temperature that decreases more than 66 °C (150 °F) below the average operating temperature Most landfill applications will generate some deposits may indicate the misfire of a . Inspect the in the combustion chamber and in the turbocharger. spark plug in accordance with the engine Operation Siloxanes are a major contributor to these deposits. and Maintenance Manual, “ Spark The fuel requires treatment in order to remove the Plug - Inspect/Adjust/Replace” article. siloxanes. For information on equipment for processing landfill gas, refer to the most current Note: For more information on bio-gas, refer to the revision level of Special Publication, LEBW4977, most current revision level of Special Publication, “Gaseous Fuels - Application and Installation Guide”. LEBW4977, “Gaseous Fuels - Application and Installation Guide”. Note: The amount of silicon in the fuel can be measured with a test that was developed by Digester Gas Caterpillar and by Bio-Engineering Services. The test kit enables a sample of the fuel to be analyzed. The A variety of materials can produce digester gas: fuel can also be analyzed for other harmful contaminants such as chlorines, fluorines, sulfur, and • Sewage halides. The Portable Silicon Evaluation Unit (#SI 110V) is used to process fuel samples on site, and Digester gas has properties that are similar to the the Silicon Sample Sets (#SI 20) are the fluid sets properties of landfill gas. Digester gas usually has that are processed by the Portable Silicon Evaluation some sulfur and siloxanes. However, the chlorofluorocarbons that are commonly found in Unit. The processed fluid sets are then sent to the landfill gas are not usually found in digester gas. The laboratory for analysis. Details can be obtained from same precautions for treatment of the fuel and the following address: protecting the engine are required. Until experience proves otherwise, the same maintenance Bio-Engineering Services recommendations are used. 36 Virginia Street Southport, Merseyside PR8 6RU England • Ag Biogas Telephone 44 (0) 1704-539094 Fax 44 (0) 1704-501660 Note: Caterpillar is not responsible for the performance or quality of aftermarket products. 32 SEBU6400-06 Maintenance Section Hydrogen Sulfide Effects on Engine Maintenance Costs

Ag Biogas is a methane based fuel created from an Analyze the gas before use. If the gas has more than anaerobic digestion process of animal waste or a 0.43 mg of H2S/MJ (.450 µg of H2S/Btu), treat the combination of animal waste and agricultural gas in order to reduce the content of hydrogen products. It does not include landfill, gasifier (syngas) sulfide. or wastewater treatment plant type gas producing applications. Ag biogas usually has some variable Various devices can reduce the content of hydrogen amounts of sulfur, which can reduce maintenance sulfide. Examples are chemically active filters, intervals. Regular maintenance of the product will reactive beds, and solutions. The performance of the depend on quality of the fuel. Oil sampling and data devices deteriorates as the reactive chemicals are trending will determine optimum oil change interval. depleted. The devices must be serviced or replaced Spark plugs may have reduced life as well based on in order to maintain effectiveness. the quality of the fuel. Take the following precautions even if the gas is treated in order to reduce the level of hydrogen i01790821 sulfide. This will help to protect the engine against intervals when the devices for treating the fuel Hydrogen Sulfide Effects on deteriorate. Even brief intervals of operation with high sulfur fuels can damage the engine, unless Engine Maintenance Costs precautions are taken. SMCS Code: 1280 • Maintain the temperature of the coolant outlet to a Sour gas refers to fuels that contain more than minimum of 110 °C (230 °F). Do not allow the rise

0.43 mg of H2S/MJ (0.450 µg of H2S/Btu). The in temperature across the engine to exceed 8.3 °C following gases are within this category: (15 °F). A rise in temperature of 5.6 °C (10 °F) is preferable. • Some wellhead gases Lower jacket water coolant temperatures permit • Landfill gas water vapor and hydrogen sulfide to condense on the cylinder liners. Higher temperatures will reduce this • Digester gas condensation. Sweet gas pertains to fuels that have less than • Establish an oil analysis program in order to 0.43 mg of H2S/MJ (.450 µg of H2S/Btu). Typically, ensure that the oil change intervals are not propane and processed dry natural gas are in this extended beyond the condemning limits of the oil. category. The oil analysis will also be able to detect other problems that may occur. Without precautions, maintenance costs are greatly increased by the introduction of hydrogen sulfide into the engine's fuel. For sour gas, Caterpillar i03129864 recommends engine arrangements for landfill gas. Hydrogen Sulfide Effects on The use of gases that have hydrogen sulfide can damage the engine. Products of combustion (water Engine Maintenance Costs vapor and sulfur oxides) form sulfurous acid and SMCS Code: 1280 sulfuric acid. Sulfur reacts easily with bright metals such as copper. Therefore, oil coolers are usually the The use of gases that have hydrogen sulfide can first components that are affected by the acids. Other damage the engine. Products of combustion (water engine parts that are attacked by the acids include vapor and sulfur oxides) form sulfurous acid and the following components: sulfuric acid. Sulfur reacts easily with bright metals such as copper. Therefore, oil coolers are usually the • Valves first components that are affected by the acids. Other engine parts that are attacked by the acids include • Valve guides the following components:

• Piston pin bushings • Fuel valves • Piston rings • Valve mechanisms

• Cylinder liners • Piston pin bushings • Exhaust manifolds • Piston rings

• Aftercoolers • Cylinder liners • Exhaust manifolds SEBU6400-06 33 Maintenance Section Fuel Filtration

• Aftercoolers For many gas engines, fuel filters are a provision of the design for the application. These devices are Various devices can reduce the content of hydrogen included in the normal maintenance of the plant. sulfide. Examples are chemically active filters, Therefore, Cat does not include a standard reactive beds, and solutions. The performance of the as a part of each gas engine. However, fuel filters are devices deteriorates as the reactive chemicals are available from your Cat dealer. depleted. The devices must be serviced or replaced in order to maintain effectiveness. Note: Use a fuel filter that is designed to capture Take the following precautions even if the gas is a minimum of 99 percent of the particles that are treated in order to reduce the level of hydrogen 1 micron in diameter. sulfide. This will help to protect the engine against Consult your Cat dealer about the requirements for intervals when the devices for treating the fuel filtering your fuel. deteriorate. Even brief intervals of operation with high sulfur fuels can damage the engine, unless Table 11 precautions are taken. Inlet & Filter Group 1.0 Micron .01 Micron Outlet • Use an engine configuration that has a fuel system 1 1/4 inch that is designed for sour gas and a positive 321-6969 4P4719 crankcase ventilation system.. NPTF 2 inch NPTF 321-6970 4P4720 140-1125 • Maintain the temperature of the coolant outlet to a minimum of 110 °C (230 °F). Lower jacket water 3 inch NPTF 321-6971 4P4721 140-1126 coolant temperatures permit water vapor and hydrogen sulfide to condense on the cylinder liners. Higher temperatures will reduce this condensation. Do not allow the rise in temperature across the engine to exceed 8.3 °C (15 °F). A rise in temperature of 5.6 °C (10 °F) is preferable. • Establish an oil analysis program in order to ensure that the oil change intervals are not extended beyond the condemning limits of the oil. The oil analysis will also be able to detect other problems that may occur. For additional information on gaseous fuels and on treatment of the fuel, refer to the following publication: • Special Publication, LEBW4977, “Gaseous Fuels - Application and Installation Guide”

i04127289 Fuel Filtration SMCS Code: 1260; 1280

NOTICE The customer is responsible for supplying clean, dry fuel to the engine. Fuel filters are no less important than air filters to protect gas engines from dirt and debris. A prop- er fuel filter removes impurities that can damage the internal components of the engine.

The gas must be supplied to the engine at a pressure that is acceptable. For optimum operation, use a fuel filter that is properly sized for the gas pressure. 34 SEBU6400-06 Maintenance Section Cooling System Specifications

Cooling System Many engine failures are related to the above conditions: cracking of the cylinder head and/or of the Specifications , piston seizure, leakage of the water pump, failure of the water pump and pitting of the cylinder liners and cylinder block. i06579726 These problems can be avoided through proper General Coolant Information maintenance of the cooling system. Periodically evaluate the maintenance practices in order to make SMCS Code: 1350; 1395 sure that the cooling system is properly maintained.

NOTICE Properties of Coolant/Antifreeze Refer to the engine Operation and Maintenance Manual for any coolant information that may be Coolant/antifreeze is normally composed of three specific to that application. elements: water, glycol and additives. Each element must meet specific guidelines. Functions of Cooling System Water

The cooling systems of modern gas engines are Water is used in the cooling system in order to precisely balanced. The performance of the cooling transfer heat. system affects many of the engine components. Optimum performance can only be obtained by NOTICE proper installation and maintenance of the cooling Never use water alone without Supplemental Coolant system. Additives (SCA) or without inhibited coolant. Water alone is corrosive at engine operating temperatures. The engine cooling system is designed to meet Water alone does not provide adequate protection specific guidelines. The proper coolant/antifreeze will against boiling or freezing. provide the following functions: • Adequate heat transfer Deionized water or distilled water is recommended for use in engine cooling systems. • Compatibility with the cooling system components If distilled water or deionized water is not available, such as hoses, seals, and piping use water with the properties that are listed in Table 12 . • Protection from water pump cavitation Table 12 • Protection from other cavitation erosion Caterpillar Minimum Acceptable Water Requirements

• Protection from freezing and from boiling Property Maximum Limit ASTM Test

40 mg/L “D512”, • Protection from the buildup of corrosion, of sludge, Chloride (Cl) and of scale (2.4 grains per US gal) “D4327” 100 mg/L Sulfate (SO4) If a cooling system fails to perform any of the above (5.9 grains per US gal) “D516” functions, the following conditions can occur: 170 mg/L • Overheating Total Hardness (10 grains per US gal) “D1126” • Overcooling 340 mg/L Total Solids (20 grains per US gal) “D1888” • Leaks from hoses, from seals, and from piping Acidity pH of 5.5 to 9.0 “D1293” • Cavitation erosion • Damage from freezing or from boiling

• Plugging of passages for the coolant/antifreeze in components such as radiators, aftercoolers, oil coolers, and other heat exchangers SEBU6400-06 35 Maintenance Section General Coolant Information

Protection against freezing is reduced if the mixture NOTICE Use of water that does not meet the recommenda- has more than 50 percent of propylene glycol. tions for the cooling system will damage the cooling system. NOTICE Do not use propylene glycol in concentrations that Do not use these types of water in the cooling sys- exceed 50 percent glycol because of the reduced tem: sea water, softened water that has been condi- heat transfer capability of propylene glycol. Use ethyl- tioned with salt, hard water and tap water. ene glycol in conditions that require additional protec- tion against boiling or freezing. Only use water that meets the recommendations for the cooling system. In order to check the concentration of glycol, use the 245-5829 Coolant/Battery Tester Gp If you are not sure about the properties of your water, (REFRACTOMETER) or use the 360-0774 consult one of the following sources for a water Refractometer. The testers give readings that are analysis: immediate and accurate. The testers can be used with ethylene or propylene glycol. • Caterpillar dealer Additives • Local water utility company • Agricultural agent Note: Glycol used in finished coolants or in concentrates is inhibited using appropriate • Independent laboratory additives. Additives help protect the metal surfaces of the Glycol cooling system. A lack of coolant additives or insufficient amounts of additives enable the following Glycol in the coolant helps to provide protection conditions to occur: against boiling and freezing. • Corrosion Note: Glycol used in finished coolants or in concentrates is inhibited using appropriate • Formation of mineral deposits additives. • Rust Most conventional heavy-duty coolant/ use . In many applications, propylene • Scale glycol may also be used. In a 50/50 mixture with water, ethylene and propylene glycol provide similar • Pitting and erosion from cavitation of the cylinder protection against freezing and boiling. liner Use a mixture that will provide protection against the • Foaming of the coolant lowest ambient temperature. For a comparison of the protection against freezing, refer to Table 13 . Many additives are depleted during engine operation. Table 13 These additives must be replaced periodically. This can be done by adding Cat Supplemental Coolant Antifreeze Protection Additive (SCA). Lowest Protective Temperature % Mixture Additives must be added at the proper concentration. Glycol and Water Ethylene Glycol Propylene Glycol Overconcentration of additives can cause the inhibitors to drop out of solution. The deposits can 50 / 50 −37 °C (−34 °F) −32 °C (−26 °F) enable the following problems to occur:

60 / 40 −51 °C (−60 °F) • Formation of gel compounds

Note: 100 percent pure glycol will freeze at a • Reduction of heat transfer temperature of −23 °C (−9 °F). • Leakage of the water pump seal The minimum recommended mixture is 50 percent glycol and 50 percent water. For optimum • Plugging of radiators, of coolers, and of small performance, Caterpillar recommends a 50/50 passages mixture of a water/glycol solution. Protection against freezing is reduced if the mixture is greater than 60 percent of ethylene glycol. 36 SEBU6400-06 Maintenance Section Coolant Recommendations

For further information, see this Special Publication, In some applications, it may not be possible to install “Supplemental Coolant Additive (SCA)” article. the recommended vent lines. In these cases, automatic vent lines must be installed. Install an automatic valve that is 0.6 to 0.9 m (2.00 to 3.00 ft) Requirements for Venting of the above the highest point of the cooling system on the Cooling System engine.

In order to achieve optimum service life for the water Note: An automatic valve requires periodic service. cooled components in the gas engine, the cooling Ensure that the valve is not plugged. If coolant/ system must be able to purge air. Air can be antifreeze leaks from a valve, correct the condition introduced into the cooling system by different immediately. A valve that malfunctions can allow air means: to enter the cooling system after the engine is shut down. A vent line is always preferred over an • Air can be trapped in the cooling system when the automatic valve. system is filled or when the system is refilled. i06560371 • Air that is entrained in the mixture of coolant/ antifreeze can be released by cavitation. Coolant Recommendations • Combustion gas can leak into the cooling system. SMCS Code: 1350; 1352; 1395 For maximum service life of the water cooled components, all of the air must be purged from the General Recommendations water jacket of each component. The presence of air can allow some of the coolant/antifreeze to convert into steam. This changes the properties of the NOTICE coolant/antifreeze. Removal of the air reduces the Never add coolant to an overheated engine. Engine possibility of forming steam and improves the service damage could result. Allow the engine to cool first. life of the coolant/antifreeze. During shipping and storage, the engine must be The preferred method for venting of the engine protected from damage that can be caused by cooling system is the installation of vent lines. Follow freezing of the cooling system. If the engine is these guidelines: shipped to a site with freezing temperatures and/or if the engine is stored in a location with freezing • The vent line must be routed from the highest temperatures, the cooling system must contain point of the cooling system on the engine to a antifreeze that will withstand the lowest ambient point that is higher than any of the engine water temperature. Frequently check the concentration of cooled components. glycol in the coolant/antifreeze. Ensure that the concentration is adequate in order to prevent • Each component that is in a position which can freezing. Otherwise, the cooling system must be trap air must be vented. For example, the completely drained, including pumps and coolers.. turbocharger and the exhaust bypass valve are usually located at the highest points of the cooling For engines in any location, periodically check the concentration of the additives in the coolant/ system. One line cannot remove the air from both antifreeze. Ensure that the concentration is adequate components. If only one of the components is in order to help prevent corrosion and other harmful vented, the other component can still trap air. Both conditions. of the components must be vented. NOTICE • For each cooling circuit, route the vent line into the Never operate an engine without water temperature bottom of the expansion tank. regulators in the cooling system. Water temperature regulators help to maintain the engine coolant at the • The vent line must have a continuous upward proper operating temperature. Cooling system prob- slope. In order to avoid blockage in the vent line, lems can develop without water temperature ensure that the vent line is routed in a manner that regulators. will avoid trapped fluid. Do not allow any dips in the routing of the vent line. NOTICE • Always remove the pressure cap in order to fill the Fill the cooling system no faster than 19 L (5 US gal) cooling system. Leave the pressure cap loose per minute to avoid air locks. during the first few minutes of engine operation in order to allow air to be fully purged. SEBU6400-06 37 Maintenance Section Coolant Recommendations

After a cooling system has been refilled, monitor the level of the coolant/antifreeze in the expansion tank. Maintain the level above the minimum mark until all of the air has been purged from the system. Then maintain the proper level for normal operation. During normal operation, frequently check the level of the coolant/antifreeze in the expansion tank. If the level is low, add the proper mixture of coolant/ antifreeze. For engines in any location, check the concentration of the conditioner in the coolant/antifreeze according to the engine Operation and Maintenance Manual, “Maintenance Interval Schedule”. Obtain an S·O·S coolant analysis (Level 1) or use the appropriate test kit. Ensure that the concentration is adequate in order to help prevent corrosion and other harmful conditions. To further monitor the cooling system, obtain regular S·O·S coolant analyses (Level 2) according to the engine Operation and Maintenance Manual, “Maintenance Interval Schedule”. Recommended Coolant/Antifreeze

NOTICE Do not use Extended Life Coolant (ELC) with Cat Gas Engines. ELC was not formulated for use in Cat Gas Engines. Do not use heat transfer fluids in Cat Gas Engines. Use only the coolant/antifreeze that is recommended.

The coolants that are recommended or acceptable for use in Cat Natural Gas Engines are listed in Table 15 . Table 14 Recommendations For Finished Coolants For Use In Cat Natural Gas Engines

Required Mainte- Coolant Type Service Hours(1) (2) Recommendation Product nance(3)

SCA at maintenance Preferred Cat NGEC 3000 hours or 3 years interval

Cat DEAC SCA at maintenance Acceptable 3000 hours or 3 years Cat SCA (water based)(4) interval Cat NGEC, Cat DEAC, ASTM D6210 and Nitrite Cat SCA, Commercial (NO2) with the concentra- Conventional Coolants Min requirements for fully tion: Min of 1200 ppm SCA at maintenance formulated heavy duty and max of 2400 ppm. 3000 hours or 2 years interval commercial coolants Silicon concentration: min of 100 ppm and max of 275 ppm

(continued) 38 SEBU6400-06 Maintenance Section Coolant Recommendations

(Table 14, contd) Recommendations For Finished Coolants For Use In Cat Natural Gas Engines

Required Mainte- Coolant Type Service Hours(1) (2) Recommendation Product nance(3)

ASTM D4985(4) and Ni-

trite (NO2) with the con- Min requirements for centration: Min of 1200 SCA at maintenance commercial coolants re- ppm and max of 2400 3000 hours or 1 year interval quiring SCA precharge ppm. Silicon concentra- tion: min of 100 ppm and max of 275 ppm

Commercial supplemen- tal coolant additive and

water having Nitrite (NO2) Min requirements for with the concentration: SCA at maintenance commercial SCA and 3000 hours or 1 year Min of 1200 ppm and interval water(5) max of 2400 ppm. Silicon concentration: min of 100 ppm and max of 275 ppm (1) New Coolants at 50 volume percent diluted. Coolants that are prediluted at the coolant manufacturer must be diluted with water that meets Reagent 4 “ASTM D1193” requirements. (2) Maintain the in-service coolant at the given limits. (3) For appropriate maintenance procedures, refer to the details given in this procedure. For applications that allow the use of SCA and water, a minimum of 6 percent to a maximum of 8 percent concentration of Cat SCA are recommended. (4) Water-based coolants are not allowed for use in machines that has NOx reduction aftertreatment devices, in engines that has AATAC and in Marine engines that have SWAC. (5) There are currently no industry standards to define the quality of water-based conventional coolants. In order to control the quality of SCA and water coolants, the commercial SCA additive package should pass ASTM D6210 and/or ASTM D4985 when this package is used in a glycol based coolant. Do not use a commercial SCA additive package that only meets the ASTM D3306 or equivalent specification when used in a glycol based coolant.

Preferred – Cat Natural Gas Engine Coolant NOTICE (NGEC) Do not use a commercial coolant/antifreeze that only meets the ASTM “D3306” or equivalent specification. Cat coolants have been developed and tested in This type of coolant/antifreeze is made for light duty order to provide the full performance and service life automotive applications. that has been designed and built into Cat cooling systems. Cat NGEC coolant is currently used to fill Use only the coolant/antifreeze that is recommended. Cat gas engines at the factory. This coolant is offered by Caterpillar dealers for continued use when the Acceptable – In applications that do not require coolant is changed. Consult your Caterpillar dealer protection from boiling or from freezing, a mixture of for more information on Cat coolants. Cat SCA and water that meets the properties that are Alternatively, use Cat Diesel Engine Antifreeze/ listed in the “Caterpillar Minimum Acceptable Water Coolant (DEAC) or a commercial heavy-duty coolant/ Requirements” Table in the “General Coolant antifreeze that meets “ASTM D6210” or “ASTM Information” topic is acceptable. D4985” specifications. Commercial coolants are, as a group, second choice. Note: The preferred coolant/antifreeze and the acceptable mixture of SCA and water require Commercial heavy duty coolant/antifreeze can different concentrations of SCA. Refer to the contain either ethylene glycol or propylene glycol. “Supplemental Coolant Additive (SCA)” topic. The coolant/antifreeze must contain 200 ppm (parts per million) silicates to 500 ppm silicates in Table 15 is a list of the coolant/antifreeze that is concentrate or 100 ppm to 275 ppm silicates in a 50/ recommended for Cat Gas Engines. The service life 50 mix. The coolant/antifreeze must be mixed with of the coolant/antifreeze that is used in Cat Gas water that meets the properties that are listed in the Engines is also listed. In order to achieve this Table in the “General Coolant Information” topic. The service life, the coolants must be properly coolant/antifreeze must also have the correct maintained. The maintenance program includes concentration of Supplemental Coolant Additive S·O·S coolant analysis. (SCA). SEBU6400-06 39 Maintenance Section Supplemental Coolant Additive (SCA)

Table 15 Recommended Coolant/Antifreeze and Service Life of the To ensure that the correct amount of SCA is in the Coolant/Antifreeze cooling system, the concentration of SCA must be

(1) tested on a scheduled basis. Obtain an S·O·S Coolant/Antifreeze Service Life coolant analysis (Level 1) or use a test kit to check Cat NGEC the concentration of the SCA according to the engine Three Years Operation and Maintenance Manual, “Maintenance Cat DEAC Interval Schedule”. Commercial Heavy-Duty Cool- ant/Antifreeze that meets Two Years “ASTM D6210” Commercial Heavy-Duty Cool- Cooling system coolant additive contains alkali. ant/Antifreeze that meets One Year To help prevent personal injury, avoid contact “ASTM D4985” with the skin and eyes. Do not drink cooling sys- tem coolant additive. Cat SCA and Water Two Years Commercial SCA and Water One Year (1) The service life of coolant is also limited by use (service hours). Coolant/Antifreeze and SCA Refer to the specific engine Operation and Maintenance Man- ual, “Maintenance Interval Schedule”. Note: Mixtures of glycol and water require a lower concentration of SCA than mixtures of only water and i05966687 SCA. Mixtures of glycol and water require 3 to 6 percent of SCA. Supplemental Coolant NOTICE Additive (SCA) Do not exceed the recommended six percent supple- SMCS Code: 1350; 1352; 1395 mental coolant additive concentration. Test the concentration of the SCA with an S·O·S Recommended Supplemental coolant analysis (Level 1) or with the 4C-9301 Coolant Additive (SCA) Coolant Conditioner Test Kit. Instructions are provided with the 4C-9301 Coolant The use of SCA helps to prevent the following Conditioner Test Kit. conditions from occurring: Note: Cat SCA has a nitrite base. Many commercial • Corrosion types of SCA have a base of phosphate that cannot be checked with a Caterpillar test kit. If a commercial • Formation of mineral deposits SCA is used, follow the recommendations for testing • Cavitation erosion of the cylinder liners that are provided by the OEM of the product. If a commercial SCA is used, the final mixture of • Foaming of the coolant coolant/antifreeze must have 1400 mg/L (82 gr per US gal) or 1400 ppm of nitrites. Preferred – Cat Supplemental Coolant Additive (SCA) Maintain a concentration level of nitrites in the cooling system that is between 1200 mg/L Acceptable – A commercial SCA that provides 1400 mg/L (82 gr per US gal) or 1400 ppm of nitrites (70 gr per US gal) and 2400 mg/L in the final mixture of coolant/antifreeze (140 gr per US gal). Water and SCA Note: A 50/50 concentration of Cat NGEC or of Cat DEAC does not require a treatment with an A cooling system that uses a mixture of water and SCA at the initial fill. Commercial heavy-duty SCA requires more SCA than a cooling system that coolant/antifreeze that meets “ASTM D6210” or uses a mixture of glycol and water. The mixture of “ASTM D4985” specifications may require a water and SCA requires 6 to 8 percent of SCA. treatment with an SCA at the initial fill. Read the label or the instructions that are provided by the OEM of NOTICE the product. Do not exceed the recommended eight percent sup- plemental coolant additive concentration. Commercial SCAs, as a group, are second choice additives. 40 SEBU6400-06 Maintenance Section Cooling System Maintenance

Test the concentration of SCA with an S·O·S coolant Table 17 analysis (Level 1) or with the 4C-9301 Coolant Conditioner Test Kit. Follow the instructions that Quantities and Part Numbers of Cat Diesel Engine Anti- come with the kit, including the addition of SCA if freeze/Coolant (DEAC) needed. Type 3.8 L (1 US gal) 208 L (55 US gal)

Undiluted Excessive Concentrations of SCA 339-3768 339-3769 Concentrate An excessive concentration of SCA can result in the formation of deposits. Table 18 If the concentration of SCA is greater than the Quantities and Part Numbers of Cat Supplemental Coolant recommended level, drain some of the coolant/ Additive (SCA) antifreeze. Refill the cooling system with water and 18.9 L 208 L operate the engine in order to dilute the mixture. 0.47 L (1 pint) 0.95 L (1 qt) Then, test the concentration again. Repeat this (5 US gal) (55 US gal) process until the concentration is acceptable. 8T-1589 3P-2044 8C-3680 5P-2907

i06580125 Cooling System Maintenance SMCS Code: 1350; 1352; 1395 Cooling system maintenance has a direct effect on engine operation and on the service life of the engine. Maintain the coolant to the standards that are recommended in the engine Operation and Maintenance Manual. Refer to the Operation and Maintenance Manual, “Maintenance Interval Schedule”. Follow these guidelines:

• Use the recommended coolant/antifreeze. • Maintain the proper concentration of Supplemental Coolant Additive. Use the correct method of testing. • Maintain the protection against freezing.

• Clean the cooling system and refill the system according to the engine Operation and Maintenance Manual.

• Consult your Caterpillar dealer about S·O·S Coolant Analysis.

Note: Cat cleaners can be used in order to clean the cooling system. Follow the instructions on the label. Consult your Caterpillar dealer for availability. Fluid Products for the Cooling System

Table 16 Quantities and Part Numbers of Cat Natural Gas Engine Coolant (NGEC)

3.8 L 19 L 208 L Type (1 US gal) (5 US gal) (55 US gal)

50% Glycol 339-3776 339-3777 339-3778 50% Water SEBU6400-06 41 Maintenance Section S·O·S Services Coolant Analysis

Table 19 Quantities and Part Numbers of Cat Cooling System Cleaner - Quick Flush 3.8 L 18.9 L 208 L 0.95 L (1 qt) (1 US gal) (5 US gal) (55 US gal)

4C-4610 4C-4611 4C-4612 4C-4613 Test Tools for the Cooling System

Table 20 Test Tools for the Cooling System and Function of the Tools

Part Function Coolant/Battery Tester Gp 245-5829 Check the freezing point of the coolant/antifreeze. 360-0774 Refractometer 4C-9301 Coolant Conditioner Test Kit Check the concentration of the SCA in the coolant. 4C-9297 Test Strip (Coolant Conditioner) Test strips for checking the concentration of the SCA in mixtures of glycol and water

164-3310 Infrared Thermometer 164-3320 Infrared Thermometer Gp (110 Volt AC Adapter) Measure surface temperatures without contacting the surface.

166-9030 Infrared Thermometer Gp (220 Volt AC Adapter)

i03155761 • The application of the equipment S·O·S Services Coolant Analysts at Caterpillar S·O·S fluid labs are trained to determine the acceptability of coolants. These Analysis analysts have knowledge of the equipment and applications. These qualifications enable the analysts SMCS Code: 1350; 1352; 1395; 7542; 7542-008 to detect problems before damage occurs. Testing the engine coolant is important to ensure that the engine is protected from internal cavitation and NOTICE from corrosion. The analysis also tests the ability of Always use a designated pump for oil sampling, and the coolant to protect the engine from boiling and use a separate designated pump for coolant sam- from freezing. pling. Using the same pump for both types of sam- ples may contaminate the samples that are being Coolant analysis can be performed at your Caterpillar drawn. This contaminate may cause a false analysis dealership. Caterpillar S·O·S coolant analysis is an and an incorrect interpretation that could lead to con- excellent way to monitor the condition of your coolant cerns by both dealers and customers. and your cooling system. The most critical aspect of coolant analysis is the Caterpillar S·O·S coolant analysis is a program with interpretation of the results. The analyst must be two levels. The program is based on periodic properly trained in order to provide a correct samples. The samples are analyzed. The results are diagnosis. The analyst must understand several reported, and appropriate recommendations are variables. made according to the results. Different coolants have different formulations and S·O·S Coolant Analysis (Level 1) different condemning limits. Different commercial labs may use different methods to test for the same variable. These other considerations are also A coolant analysis (Level 1) is a test of the properties important for interpreting the results of a coolant of the coolant that includes the following items: analysis: • Glycol concentration for protection from boiling • The number of hours on the sample and freezing

• The equipment that uses the coolant • Ability to protect from erosion and corrosion 42 SEBU6400-06 Maintenance Section S·O·S Services Coolant Analysis

• pH • Conductivity

• Water hardness • Visual analysis

• Analysis of the odor The results are reported, and appropriate recommendations are made. S·O·S Coolant Analysis (Level 2)

A coolant analysis (Level 2) is a comprehensive chemical evaluation of the coolant. This analysis is also a check of the overall condition of the inside of the cooling system. The following services are provided: • Full Level 1 analysis

• Identification of the source of metal corrosion and of contaminants • Identification of buildup of the impurities that cause corrosion • Identification of buildup of the impurities that cause scaling • Determination of possible electrolysis within the engine cooling system The results are reported, and appropriate recommendations are made. For more information on S·O·S coolant analysis, consult your Caterpillar dealer. SEBU6400-06 43 Reference Information Section Reference Materials

Reference Information Section

Reference Materials

i06584629 Reference Material SMCS Code: 1000 Additional literature regarding your product may be purchased from your local Cat dealer or by visiting www.cat.com. Use the product name, sales model, and serial number in order to obtain the correct information for your product. 44 SEBU6400-06 Index Section

Index

A G Aftermarket Oil Additives...... 15 General Coolant Information...... 34 Functions of Cooling System...... 34 B Properties of Coolant/Antifreeze ...... 34 Requirements for Venting of the Cooling Bio-Gas...... 30 System ...... 36 Digester Gas...... 31 General Fuel Information ...... 28 Landfill Gas...... 30 General Lubricant Information ...... 5 Cat Fluids...... 5 C Commercial Oils...... 9 H 7000 Hour Field Performance Evaluation ..... 9 Hydraulic Oil ...... 20 Coolant Recommendations...... 36 Applications ...... 20 General Recommendations...... 36 Cat Bio HYDO Advanced (Hydraulic Oil) ... 21 Recommended Coolant/Antifreeze ...... 37 Cat HYDO Advanced Hydraulic Oils, SAE Cooling System Maintenance ...... 40 10W, SAE 20W, and SAE 30 ...... 21 Fluid Products for the Cooling System ...... 40 Commercial Oils ...... 22 Test Tools for the Cooling System ...... 41 Hydrogen Sulfide Effects on Engine Cooling System Specifications...... 34 Maintenance Costs...... 32

D I Dry Natural Gas (Pipeline) ...... 30 Important Safety Information...... 2

E L Engine Oil...... 7 Lubricant Specifications ...... 5 Cat Gas Engine Oils ...... 7 Lubricating Grease...... 23 Engine Oil and Bio-Gas Fuels ...... 8 Cat Ball Bearing Grease...... 26 Engine Oil and Sour Gas Fuels ...... 8 Cat Extreme Application Grease ...... 24 S·O·S Services Oil Analysis ...... 9 Cat Extreme Application Grease-Arctic (Semi- Synthetic)...... 25 F Cat Extreme Application Grease-Desert ..... 25 Cat Prime Application Grease ...... 24 Field Evaluation of Commercial Oil...... 9 Cat Utility Grease...... 23 Criteria for the Evaluation ...... 11 Cat White Assembly Grease ...... 24 Guidelines for the Use of A Proven Lubricant Grease Application Charts...... 26 In Other Engines (Interchanging) ...... 13 Hammer Grease ...... 24 Operating Conditions for the Field Moderate Applications...... 23 Performance Evaluation ...... 10 Severe Applications...... 24 Responsibilities...... 12 Foreword ...... 4 Literature Information ...... 4 M Maintenance ...... 4 Maintenance Section...... 5 Safety...... 4 Fuel Effects on Maintenance Costs ...... 29 O Fuel Filtration...... 33 Fuel Specifications ...... 28 Oil Change Interval (and Oil Sampling)...... 16 SEBU6400-06 45 Index Section

P Propane...... 29

R Re-refined Base Stock Oils ...... 15 Reference Information Section ...... 43 Reference Material...... 43 Reference Materials ...... 43

S S·O·S Services Coolant Analysis ...... 41 S·O·S Coolant Analysis (Level 1)...... 41 S·O·S Coolant Analysis (Level 2)...... 42 S·O·S Services Oil Analysis...... 16 Corrosive Gaseous Fuels...... 17 S·O·S Services Oil Analysis Guidelines...... 18 Silicon Containing Gases ...... 17 Sour Gas ...... 30 Supplemental Coolant Additive (SCA)...... 39 Recommended Supplemental Coolant Additive (SCA) ...... 39 Synthetic Base Stock Oils ...... 15

T Table of Contents ...... 3

W Wellhead Gas...... 29

Product and Dealer Information

Note: For product identification plate locations, see the section “Product Identification Information” in the Operation and Maintenance Manual.

Delivery Date:

Product Information

Model:

Product Identification Number:

Engine Serial Number:

Transmission Serial Number:

Generator Serial Number:

Attachment Serial Numbers:

Attachment Information:

Customer Equipment Number:

Dealer Equipment Number:

Dealer Information

Name: Branch:

Address:

Dealer Contact Phone Number Hours

Sales:

Parts:

Service: SEBU6400 CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow”, and the POWER EDGE trade ©2016 Caterpillar dress as well as corporate and product identity used herein, are trademarks of Caterpillar and All Rights Reserved may not be used without permission.

48 February 2016